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Instruction Manual

1. ii 3 2 3 2 4 CompressorDisassembiySeguence 3 6 520 Disass mbling Each Secliohi spa ps a 3 6 29 nes Nati 3 28 3 4 Disassembly and Reassembly of Unloader Indicator Assembiy 3 46 3 4 1 Components of Unloader Indicator Assembly sse eee eee ee 3 46 342 O ua aaa aaa adla alayla le 3 49 pk e ga e 3 49 3 4 4 Reassembly boss kayak iel e a ka daa pia adadaki 3 49 l ndan 4 1 Contact information Chapter 1 Principle of Operation and Construction 1 1 General MYCOM SCV Series Screvv Compressors are rotary compressors falling into the category of the positive displacement compressor The compressor sucks refrigerant gas into a cavity gradually reduces the volume of the cavity and discharge the refrigerant as a high pressure gas More specifically a sealed cavity is formed by a casing and a pair of intermeshing rotors called the male and female rotors in the casing The rotors are different in lead and number of screvv lobes The volume of the sealed cavity gets reduced as the rotors rotate The gas trapped in the cavity is thus compressed before it is discharged The SCV Series models feature a mechanism for readily changing the internal volume ratio Vi which refers to the ratio between the volume of the cavity j
2. 1 15 1 6 Components and External DIMENSIONS 888 8888888888 283322 23333333333 33 1 16 LOT Componehis Ks Te le a el a A asa ea 1 16 1 0 Perissinotto 1 19 TE 1 34 164 DIMENSIONS ANG Welt ds dd l si aa 1 37 Chapter 2 Essential Points for Operation C Ola mi cs O eR 2 1 2 2 Points to Be Observed When Operating the Compressor 2 1 2 3 CONNECING PONS on OD S SOL sa amaaan ba nil aia 2 2 24 o T 15521516 lt M R m 2 3 2 4 1 Considerations to Take When Using Vi Adjusting Mechanism eee eee 2 3 24 2 F OVU 0 5d US 1 heVio n ul m Bus 3 2 3 2 o na n aaa olasan alo b la aa wane 2 8 Selection of Lubrication aia ded h ak pe at 2 8 2 5 2 Recommended Lubrication Oils ii 2 9 2 5 3 When Changing to Different Brand s OI see 2 11 2 5 4 Points to Be Noted for Handling of Lubrication 2 12 2 5 9 Quality Management of Lubrication eee 2 12 2 5 6 Lubrication Oil Replacement 15 2 14 Chapter 3 Maintenance 3r dei 3 1 3 2 Disassembly and Inspection tin ice 3 1 3 2 1 Preparation for Disasseimbiy eee a ad ad 3 1 3 2 2 Necessary Tools Materials and iii 3 2 3 2 3 Removing the Compressor from the Base
3. 27 MainBearing 1 50270 l60 2 aa 3 side Bearing esoaao prt isem a opa 29 StopRing NGIH0O2 O Ho 4 4 4 4 4 30 Balance Piston CS03000 160H 100 H 1 1 1 1 1 1 31 Key Balance Piston 503100 1600 i60 1 1 1 1 1 1 32 Stop Ring 7 NGI20 SS L L 1717111 33 o Sleeve Balance Piston 1C803300 160H 160 H 1 1 1 1 1 1 34 NA836060iS moxis___ 2 2 2 2 2 2_ ego Ss T H E CT gt gt 24212121212 2 BE Se Bi ZA HE SEE SA HE S HE 35 O Ring 12 095 1 8B2401695 36 OF Ring Space 17 37 Stop Ring UC NG 1802 38 ThrustBearing 503800 1600 172128 39 LockNut 05 o NG31012 ANI O 40 Lock VVasher 0 NG32 012 JAW 41 Spacer Thrust Bearing CS04100 160 160 Outer Race 1 20 Spacer Thrust CS04200 160 160 2 2 2 gt 2 2 H time N A 43 ThrustBearingGland 504300 1600 160 2 2 2 2 2 2 45 o HexagonHeadBolt 15510 3 020 8 8 8 8 8 8 tao ud lann pepe hexagon head bolt lock washer CS0469 D 160 48 Retainer OilSeal_ 504800 60 1160 1 1 1 1 1 ee rao ie tt 50 OilSeal 7 98CS05010 160VD SALI55x70x9 1 1 1 1 1 1 51 SealCover_____ CSOSIO00 160BBS 160 1 1 1 1 1 1 52 o Gasket Seal Cover 1CS05200 160N t60 1 1 1
4. R l SCV eries Soren compresse rio Meri GOVSD 160VMD 160VLD 200VSD 200VMD 200VLD 250VSD 250VMD 250VLD 250VLLD 320VSD 320VMD 320VLD 160VSG 160VMG 160VLG 200VSG 200VMG 200VLG 250VSG 250VMG 250VLG 250VLLG About this Manual This instruction manual is for the MYCOM SCV Series Screw Compressors produced by Mayekavva Mfg Co Ltd for refrigerating applications hereafter collectively called the product The manual contains information on the construction and principle of operation essential points to be observed during operation and instructions for servicing and maintenance of the product The manual applies to the product models listed below If any part of the manual applies only to specific models such part is identified by indicating the applicable models 160VSD 160VMD 160VLD 200VSD 200VMD 200VLD 250VSD 250VMD 250VLD 250VLLD 320VSD 320VMD 320VLD 160VSG 160VMG 160VLG 200VSG 200VMG 200VLG 250VSG 250VMG 250VLG 250VLLG Keep this manual handy for ready reference by all persons working on the product If the manual is lost or damaged contact any of the offices or sales service centers listed at the end of this manual to order a new copy If you have anything in doubt about the information in this manual please feel free to contact any of the office or sales service centers listed at the end of this manual This manual must re
5. o L i o a I a I 1 f 2 S 5 i 2 High Vi condition Low Vi condition b i Ps 3 Rotor angle Rotor angle Necessary compression ratio and Vi are both low Necessary compression ratio and Vi are both high B Improperly adapted Vi to load condition Suction Compression _ Discharge _ Suction Compression _ Discharge Suction port closed Suction port closed 2 Discharge port E 3 9 x i 5 PE Discharge port open l En En i E E O Pd 9 5 Low Vi and high compression tn S ratio operation i a i a Ps l m 5 3 High Vi and low compression Ps ratio operation i E Rotor angle Rotor angle Too low Vi compared with necessary Too high Vi compared with necessary compression ratio compression ratio Fig 1 11 Proper and Improper Adaptation of Vi to Load Condition 1 7 Chapter 1 Principle of Operation and Construction 1 3 3 Variable Vi Mechanism The combination of the following two factors determines the Vi value 1 The size of the axial port in the bearing head port extending in the rotor axis direction 2 The size of the radial port in the unloader slide valve port extending in the direction perpendicular to the rotor axis direction The conventional fixed Vi MYCOM compressors have axial and radial ports both fixed to the sizes corresponding to the L M or H port The SCV Series compressors also have a fi
6. 3 39 Chapter 3 Maintenance yi sa er a Fig 3 100 Measuring Runout of Shaft Fig 3 101 Installing the Balance Piston g Hold the balance piston with the eye bolts screwed into the holes in the piston Install the balance piston by pressing it onto the male rotor shaft while aligning its keyvvay with the key on the shaft see Fig 3 101 Retain the piston with the stop ring 6 Bearing Cover a Fit the thrust washer P N 449 on the Vi adjusting rod see Fig 3 103 There is a gland for the Vi adjusting rod on the 320 models see Fig 3 102 b Screw long safety bolts with their heads removed into the bearing head see Fig 3 104 Apply compressor oil to the bearing head gasket set it in position on the bearing head then install the bearing cover For the 250 and 320 models the bearing cover has a threaded hole for installing a hanging bolt in its center of gravity position With the bearing cover suspended from a crane using the hanging bolt install the bearing cover to the bearing head while keeping the clearance between the two components peripheries so as not to damage the mechanical seals First screw in a pair of bolts at diagonally opposite positions evenly and alternately until the entire bearing cover comes in contact with the bearing head and then fasten the remaining bolts see Fig 3 105 Fig 3 102 Vi Adjusting Rod 320 Models Fig 3 103 Installing the Thrust Washer 3 40 Fig 3 105 Insta
7. 444 ViAdjustingRod 1 6844400 320VSD 320VSD___ 2 444 ViAdjustingRod 944400 320 320 __ _ 1 444 Vi Adjusting 0h CS44400 320VLD 320VLD J 1 446 ViSquareWasher 544600 250 25009 4 1 1 1 448 Teflon Bushing o o Csiis00320 D o J o TT E Washer_CS44900 320Vb__ ____ 2 2 07 61 O A A si TO Ring A 452 Hexagon Socket Head Cap NB35406 020 M x 20 1 1 1 ll sca xl Km 1 S NS ri ci l l 522 Domed CapNut NC921 36 M6 1 1 I 523 1 0 Ring 7 PA11 0504 JISB2401P50A 1 f 1 f 1 528 Sleeve OilSeal_______ CS52800 320VD__ J 1 1 1I 529 Set Serevv UC 1NA83606 010 1M6x8 200533 2 2 2 533 SpringWasher____ ND33006 595 599 GuidePin 1 206 01 o 66x16 J 1 121 600 Retainer Vi Adjusting Rod 560000 320 0 320V 077 1 1 601 Lubrication Oil Inlet CR74000 020 o o MYK20 J 1 1 1I 602 Gasket Lubrication Oil Inlet CR72000 020N MYK20A 1 1 1 ul 603 Hexagon Head Bolt 91NB14012 035 MI2x35 2 2 7 2 2 604 Vi Adjusting Rod Washer liShi256636 L T_T 160531 T 2 0 y iO _ 1 1 0 TV A 607 A Plug 000 NF06004 RA 1 1 1 1 32 Pu NFO6 004 R 1 4 Conical Spring Washer MBG 680 B Conical Spring Washer E ELE SEO 5 m 1 33 Chapter 1 Principle of Operation and Construction 1 6 3 Sectional
8. 8 Unloader indicator assembly 9 Anchoring bolts 4 places nm mim ET Fig 3 1 Disconnection Sequence 3 3 Chapter 3 Maintenance 3 Lifting and Moving the Compressor to VVorkbench e Only a qualified person must carry out lifting and moving operation of the compressor e Disassembling and reassembling operation on a lifted compressor is extremely dangerous and should be avoided at all cost Instead support the compressor with a rigid stand and take every measure to prevent it from slipping off before starting the service work a Remove the compressor from the base When doing this operation pay attention to the suction strainer at the top not to induce stress in the suction piping b Cover the suction cover flange with a plastic sheet or wooden board to prevent foreign materials from entering the compressor c Lift and move the compressor toward the workbench see Fig 3 2 Place the leg part of the suction cover on the workbench and support the remaining part of the compressor at the leg part of the bearing head on a stand of the same height as the workbench see Fig 3 3 so that lower hexagon socket head cap screws can be removed a K Fig 3 2 Lifting and Moving the Compressor Fig 3 3 Preparation for Removing Lower Screws 3 4 Y N DH k ozu Fig 3 4 Removing Lovver Screvvs d Ofthe hexagon socket head cap screvvs P N 2 fastening both the bearing head and suction cover to the m
9. Fig 3 64 Installing the Main Bearings Fig 3 65 Bearing Installation Jig b There is a pin in each main bearing bore in the bearing head which serves both as a locking and alignment pin Fit each main bearing while aligning its notch with the pin c Install the stop ring to retain each bearing d Make sure the O ring P N 451 is fitted in the hole for the Vi adjusting rod e Apply oil to both surfaces of the gasket to be fitted between the bearing head and main rotor casing Affix the gasket to the main rotor casing and hold it on the main rotor casing by inserting a screw into the casing Since the holes in the gasket are not arranged symmetrically make sure the holes in the gasket exactly align with the holes in the main rotor casing 3 28 2 Main Rotor casing Unloader Slide Valve Variable Vi Auxiliary Slide Valve and Bearing Head a Unloader slide valve Check that the Vi adjusting rod s Teflon bushing P N 448 on the unloader slide valve has no defects see Fig 3 66 Replace the O ring P N 523 fitted in the Vi adiusting rod hole of the unloader slide valve the hole is located on the valve s end vvhere the unloader push rod is installed see Fig 3 67 Fig 3 66 Teflon Bushing for Vi Adiusting Rod Fig 3 67 O Ring for Vi Adiusting Rod b Main Rotor Casing After removing the plugs P N 458 clean the oil injection circuit holes thoroughly Fit the plugs into the original holes install the unloa
10. WAF 12 Ca t a WAF 14 s O O O WAF 17 Et OE i O WAF 19 fee di e L r 1 e 4 5 Chapter 4 Service Data Special Tools Separately Available vos 12 AN 13 ANAT 17 AN 21 Lock nut wrench AN 05 AN 07 AN 08 AN 10 Allen wrench set WAF 2 oO O WAF width across flats in mm WAF 3 e o o WAF 4 O O O WAF 5 o O O WAF 6 o O O WAF 8 L o o WAF 10 Lei WAF 12 575 5 57 e o WAF 14 Pp VVAF 17 Ss 5 i ii 0 VVAF 19 gt e O 4 6 Contact nformation For further information and questions please contact us at any of the offices and sales service centers listed belovv Japan Corporate Office 3 14 15 Botan Koto ku Tokyo 135 8482 TEL 81 3 3642 8181 FAX 81 3 3643 7094 Moriya Plant 2000 Tatsuzawa Moriya shi Ibaraki ken 302 0118 TEL 81 297 48 1361 FAX 81 297 48 5269 Hokkaido Branch 5 1 Nijuyonken 3 2 Nishi ku Sapporo shi Hokkaido TEL 81 11 631 2052 Office 063 0803 FAX 81 11 631 2053 Tohoku Branch Office 2 5 12 ldeka Miyagino ku Sendai shi Miyagi ken 983 TEL 81 22 259 5060 0012 FAX 81 22 259 5223 Hokushinetsu Branch Oyama Bdg 303 1 2 34 Bentenbashidori Chuo ku TEL 81 25 257 1626 Office Niigata shi Niigata ken 950 0925 FAX 81 25 286 6165 Kanto Branch Office 3 14 15 Botan Koto ku Tokyo 135 8482 TEL 81 3 3642 8968 FAX 81 3 3641 846
11. position The micro switch base plate P N 123 secured with screws P N 124 is located under the left micro switch so as to be able to use the outer cam of double actuator cams h Other parts can be removed by loosening their fastening screws 3 4 3 Inspection a Mainly check the contacts of electrical components As to the potentiometer check that the output resistance value varies smoothly throughout the entire rotation range of the potentiometer If the compressor is used in an atmosphere containing much moisture or corrosive gas or in a place involving relatively strong vibration also check the potentiometers internal resistance coils for probable corrosion or wear b Check operation of the micro switch contacts using a tester Also check the rotating condition of the sensor roller of each micro switch c Check the cam friction surfaces for wear and other damage 3 4 4 Reassembly and Adjustment To reassemble the unloader indicator follow the disassembly procedure in reverse After the micro switch base plate is installed on the reassembled unloader indicator the unloader cover must be adjusted a The unloader slide valve is assembled inside the unloader cylinder cover with the unloader piston set at the no load 0 position So the indicator cam is at the no load position In order to recover this original state secure the micro switch cam by screwing the set screw P N 128 in alignment with the countersink in the shaft o
12. 1 1 83 Springs Ccsos300 200 20 1 1 J 1 1 Ji 84 __ Retainer Indicator Cam Spring CS08400 200 120055 1 1 1 1 1 1 91 ShaftKey Oo CS09100200 0205 1 1 1 1 92 Flange 571400 1 55 1 1 1 1 1 1 93 Gasket Suction Flange o CR72000 15ON MYKIS0A 1 1 1 1 1 1 94 Hexagon Head Bolt 12022 055 M22x55 8 8 8 8 8 8 95 Discharge Flange 571400 125 MYK2A2 1 1 1 A a Men 1 I AA 96 Gasket G Discharge Flange CR72000 125N MYKI254 ee 97 HexagonHeadBolt NB12020 055 M20x55 97 Hexagon Head Bolt NB12020 080 M20 x 80 in Japan 100 Mechanical Seal Assembly CS10000 200BE BOSEl_____ 1 1 1 1 1 1 1 24 Mechanical Seal Assembly 1 CS10002 200EBS BBSEI 1 1 1 1 1 5 1201 Unloader Indicator Assembly CS12000 200F 07 72 71711 11 11 1 1 137 Dial UnloaderIndicator CS13700 200VD 200VL 1 1 1 1 1 1 215 o Flange Lubrication Oil Supply CR74000 020 MYK20A 1 1 1 1 1 1 ku O Gasket Lubrication Oil Supply CR72000 020N MYK20A Pp Flange a en ei CO 2 2 ME H a 235 o Spacer Discharge Flange 1FX101 200 01200 0 oa Sos AO PO E E in L L Spacer 237 Torsional Slip Washer 1 CS23700 200 1200 9 2 2 2 2 2 2 250 Thrust Washer cs2500
13. India Calle Luis Pasteur 1490 Lince Lima Peru Cordillera No 331 Modulo D14 Flex Center Puerto Vespucio Quilicura Santiago Chile Rua Licatem 250 Jardim Fazenda Rincao Polo Industrial De Aruja SP CEP 07400 000 Brazil Av Luiz Carlos Prestes 350 Sala 313 Edificio Barra Trade 1 Rio de Janeiro RJ CEP 22775 055 Brazil Rua Professor Marieta Peixoto 62 Centro Macae Rj CEP 27910 250 Brazil Bodega 63 Condominio Comercial Tierra Dos El Cacique De Rio Segundo Alajuela Costa Rica Calle Los Mangos Edificio Selemar Piso 8 Sabana Grande Caracas Venezuela Av Intercomunal Turmero EDF Techomat Metropolitano Piso 1 Oficina 3 Maracay Edo Aragua Venezuela Av De Los 50 MTS No 381 Civac Jiutepec Morelos C P 62578 Mexico Av Coyoacan 945 Col Del Valle Delegacion Benito Juarez C P 03100 Mexico D F Mexico TEL 82 55 294 8678 FAX 82 55 299 7678 TEL 82 51 242 3737 FAX 82 51 243 8542 TEL 91 12 4420 6616 FAX 91 12 4420 6618 TEL 51 1 441 8552 FAX 51 1 222 1543 TEL 56 2 739 0202 FAX 56 2 739 2700 TEL 55 11 4654 8000 FAX 55 11 4654 8002 TEL 55 21 2431 3600 FAX 55 21 2430 8882 TEL 55 22 2772 6069 FAX 55 22 2759 3112 TEL 506 2441 4464 FAX 506 2441 4465 TEL 58 212 216 6026 FAX 58 212 216 0608 TEL 58 243 269 4913 FAX 58 243 269 3952 TEL 52 77 73 19 0925 FAX 52 77 73 20 5762 TEL 52 55 5062 0870
14. Jil 1 MainRotorCasing fe 1250 L T Cap Screvv 3 AlignmentPin NE2016 070 016x7 4 4 4 4 4 4 4 4 4 HangerBot 00 38 0 T L T L T L LT LN 5 SuctionCover S00500 250 V X 250v 1 1 1 HTL T L 5 Suction Cover sowy L L 6 o Gasket Suction Cover 50061 025LDV l l l l l l l 7 HangerBot NB6012 2 2 2 2 2 2 2 2 2 8 pet NE3206 012 6x12 2 2 2 2 2 2 2 2 Ring ko PA120657 V VSB2401G65 LI T T L T L LH T 10 B l oh CK U NF06000X Ria J l l l l l l l 1017 D Pog NF605 R 0 T L T L LT L LT LH 11 Bearing Head 501100 250 2504 1 1 1 1 ii Bearing Head Ss BCS01100 250VXG 250V 6 T L T L 12 Gasket Bearing Head CS01200250N 250 0 1 1 1 1 1 1 1 1 13 Hanger Bolt C BNB600 12 M 01111 L L T L L 14 1 SpringPin BNH3206012 6x12 0 2 2 2 2 12 2 12 2 16 Bearing Cover CSOI600 250VXD 250V 1 1 1 1 16 Cover 5 hBCS01600 250VXG 250V G____ T L T LH 17 Gasket D Bearing 501700 250 0 250 4 1 1 1 1 17 Gasket G Bearing Cover____ C 01700 250VG_ 250V G T L T L 18 Hexagon Socket Head Cap NB35416 050 M16 x 50 Screw Hexagon Socket Head Cap NB35416 090 M16 x 90 eit tf od
15. s r E m7 a n Lili amm usm ir ar SP T a al EE 7 4 ci Pala i NT e ip pa PU Ha 3 GUA Br a i Fa al 1 NE gt k k a Ed m m 1 36 1 6 4 Dimensions and VVeights This section contains the dravvings and table to shovv the external dimensions and vveights of the individual SCV Series models NOTE Use the letters in the drawings as keys to dimensions in the dimension table 1 Dimension drawing 160VSD 160VMD 160VLD 200VSD 200VMD 200VLD 250VSD 250VMD 250VLD and 250VLLD models with a sideways facing discharge port 2 Dimension drawing 160VSG 160VMG 160VLG 200VSG 200VMG 200VLG 250VSG 250VMG 250VLG and 250VLLD models with a downward facing discharge port ip oum m SE 1 37 Chapter 1 Principle of Operation and Construction 3 4 Dimension dravving 320VSD 320VMD and 320VLD Dimension table mm E Mei ii A K lio ES E e Me le Le den me 4570 011 027 ui 05 0 005 1117 200VS 1199 1056 5g 10 012 ad 027 Sa 05 0 007 1311 250VS 1395 1467 670 012 4370 027 62 05 1535 0 007 0 1612 5 7 5 EA 85 0 011 2459 043 9 05 1971 751 160VS 0 a e ri m va Sir 320VSD 1 38 Model x y z a b c da e f g h i 160VS 200VS 63 3
16. As the bearing cover is heavy install the eye bolts in these holes to hang the cover using a sling to remove it Inspecting the Bearing Cover a Check the alignment pins as they would have been bent when removing the bearing cover b Inspect the thrust washer of the Vi adjusting rod Replace the washer if it is defective see Fig 3 41 c Always replace the bearing cover gasket and the bearing cover side O ring of the Vi adjusting rod 3 19 Chapter 3 Maintenance a A Fig 40 Bearing Cover Side O Ring of Vi Adjusting Rod 7 Thrust Bearings The thrust bearings P N 38 are important components that affect the performance of the screw compressor Improper installation of the thrust bearings will become a cause of operational problems of the compressor They must be handled quite carefully during both disassembly and reassembly The thrust bearings are face to face angular contact dual ball bearings each with a special retainer As the outer race of each thrust bearing is clearance fitted in the bearing head the bearing receives only thrust loads In addition to supporting thrust loads each thrust bearing has a role of precisely maintaining the clearance between the rotor end and the discharge end face of the bearing head Disassembling the Thrust Bearings a Remove the hexagon head bolts P N 45 that fasten the thrust bearing gland P N 43 Conical spring washers also come off when the bolts are removed
17. Do not lose them B Pr F vl F oer eE F 4 gt i L m Y F i m N LTT t x earing Glands 2 Fig 3 42 Removing the Thrust Bearing Glands 1 be z Fig 3 43 Removing the Thrust B 3 20 a P yr La m c Be i LS ij 74 LA FLE PI A at A N d L b dar x x F ER HR N all m Y D m e z P Peas n b ML ili MC I ni Le Pep N A LT p a tri n g T b L s m bi TAK m x Ke y A te L m E STEM Mime OOS oe o HA dk Poi a x E 1 mu Balla RI koy Ca BERE Mi Ai Fig 3 44 State after Removal of Thrust Fig 3 45 Unbending the Lock VVasher Clavvs Bearing Glands b Unbend the clavvs of the lock vvasher P N 40 holding the lock nut P N 39 vvhich retains the inner race Of each thrust bearing on the rotor shaft Then remove the lock nut c Keep the torsional slip vvasher P N 237 a thin steel plate betvveen the lock nut P N 39 and vvasher P N 40 being careful not to bend it Also keep the thrust vvasher P N 250 betvveen the lock vvasher and bearing Fig 3 46 Removing the Thrust Bearing Fig 3 47 Thrust Bearing Set d The inner race of the thrust bearing is clearance fitted on the rotor shaft Remove the thrust bearing as follows Flatten and slightly bend one end of a 2 3 mm diameter steel wire Insert the bent end of the wire into the clearance between
18. Fig 1 16 Type B Oil Supply System 1 13 Chapter 1 Principle of Operation and Construction Female rotor Return oil Male rotor Balance piston Variable Vi auxiliary slide valve Unloader slide valve Vi adjusting rod Fig 1 17 Oil Supply System 1 5 Model Designations of SCV Series Screvv Compressors The models of SCV Series Screvv Compressor covered by this manual are the follovving 160VSD 160VMD 160VLD 160VSG 160VMG 160VLG 200VSD 200VMD 200VLD 200VSG 200VMG 200VLG 250VSD 250VMD 250VLD 250VLLD 250VSG 250VMG 250VLG 250VLLG 320VSD 320VMD 320VLD The letters and numbers constituting the above model designations are interpreted as follovvs Letter V stands for the SCV Series numbers 160 200 250 and 320 represent the rotor diameters letters S M L and LL represent the rotor lengths and letters D and G indicate the discharge directions D for sidevvays discharge and G for dovvnvvard discharge NOTE The SCV Series compressors also include 400 type models which are not covered by this manual because of the difference in construction Chapter 1 Principle of Operation and Construction 1 6 Components and External Dimensions 1 6 1 Components Dravvings This section shovvs the components dravvings for the follovving models of compressor 1 160VSD 160VMD 160VLD 160VSG 160VMG 160VLG 200VSD 200VMD 200VLD 200VSG 200VMG 200VLG 250VSD 250VMD 250VLD 250VLLD 250VSG 250VMG
19. H 130 2 H 160 2 H 200 2 Balance piston S 50 1 S 65 1 S 80 1 S 100 1 Balance piston sleeve H 102 2 H 130 2 H 160 2 H 200 2 Indicator cam ball bearing S 10 1 S 10 1 5 10 1 5 10 1 Lock Nuts quantity in parentheses 160V 200V 250V 320V Thrust bearing AN12 2 AN13 2 AN17 2 AN21 2 69 Push rod unloader slide valve ANO5 1 ANO7 1 ANO8 1 AN10 1 O Rings quantity in parentheses 200V 9 Suction cover O ring spacer G60 1 G150 1 G240 1 P125 1 P200 1 73 P44 1 G135 1 G210 079 Mechanical seal BOS type P35 1 40 110 106 2 G55 1 G10 G50 1 G60 79 6x3 5 O99 6x3 5 Mechanical seal BBS III type G8 1 G13 G4 1 GI 1 i H 1 1 5 1 G90 G24 1 1 4 1 1 150 Thrustbearinggland 325 Unloader push rod O ring gland P40 2 P40 2 P58 G165 P25 1 O rings conforming to JIS W 1516 All other O rings conform to JIS B 2401 Used only for 160VS 200VS 250VS and 320VS NBR Buna N is used for all O rings as standard material 6220 017 2 Mechanical seal BBSE type P32 1 P35 P43 P110 P50 1 140259 92x3 53 69 52x2 62 291 67x3 53 1 1 2 2 1 1 1 2 2 1 1 1 1 1 1 1 2 4 4 3 Chapter 4 Service Data Gaskets 17 Bearing cover ga
20. b Install two of the removed screws into the jacking holes in the main rotor casing and screw in them alternately a little at a time to separate the suction cover from the main rotor casing and widen the clearance between them The two screws should be turned in alternately and evenly because otherwise the alignment pins would be bent When the clearance becomes adequate separate the gasket so that it remains on the suction cover c Further screw in the screws alternately until the clearance becomes wide enough to remove the alignment pins After removing the alignment pins slide the suction cover on the workbench in the direction away from the rotor casing and in line with the rotor shafts in order to separate the rotor shafts and the unloader push rod from the suction cover Do this operation while pushing the rotors toward the main rotor casing to prevent the rotors from dropping off see Fig 3 52 ea it A i i n Fig 3 52 Separating the Suction Cover Fig 3 53 Main Rotor Casing and Rotors d After separating the suction cover remove the O ring gland P N 326 at the location from which the unloader push rod was removed by removing the hexagon socket head cap screws P N 456 see Fig 3 55 To remove the O ring gland use the threaded holes for jacking bolt in the O ring gland Replece both the O ring P N 9 behind the O ring gland and the O ring P N 325 on the suction cover e Remove eac
21. msi Washer Csos000i ise aa da a 251 ElectromizerFlange 1 CR74000 025 MYK2SA J 1 1 1 1171 252 o Gasket Electromizer Flange o CR72000 025N 1 1 1 f 253 o HexagonHeadBolt 15512 0354 MI2x35 4 4 4 4 4 4 254 AquamizerFlange h CCR74000 020 MYK20A_ 1 1 1 1 1171 255 o Gasket Aquamizer Flange CR72000 020N 71T L LTLI L 171 256 Hexagon Head Bolt X NB15512 035 MI2x35 2 2 2 2 2 2 267 Special Spring Washer 1ND330 00 TMp 5 5 5 5 5 5 kd T hud gud sn i Valve o H dl Valve kum Valve 3251 1 0 Ring PA11030 HSB2401P30 2 2 2 2 2 2 326 Gland O Ring esperta a app pio 420 Spacer Unload Position s42000 160v5 reovsr 1 1 420 o Spacer Unload Position oo CS42000 160VMD 160VMF 1 1 1 J 4211 O Ring PAI10030 VISB2401P30 21 2 751 432 O Ring 12 085 SB2401G85 4 4 4 4 4 4 4331 O Ring PA12085 JISB2401685 4 4 4 4 4 4 444 Vi AdjustingRod 1C844400 160VSD 1160V88 0 1 Jif 4441 ViAdjustingRod CS44400 160VMD 160VMF J aif J 444 Vi AdjustingRod 1C844400 160VLD 160V 0097157175 011 446 Vi Square Washer CS44600 160VD__ 12 0111 11111117111 1 448 Bushing CS44800160VD__ _______ 1 1 1717111 449 Trust Washer CS44900 160
22. 1 1 1 53 Hexagon Socket Head NB35408 025 M8 x 25 Cap Screw 54 Slide Valve CS05400 160V8D 1T160V8 1 54 Unloader Slide Valve grooved 6ovss Jif 17017 54 Unloader Slide Valve CS05400 160VMD_ 160VM _ 079711 Jif 54 Unloader Slide Valve grooved 1 0 J 1 Jif A 90 54 Unloader Slide Valve grooved GE J a 58 Hexagon Socket Head NB35406 030 M6 x 30 5 gt 5 5 5 5 se ee e KAR LAR 60 o J nleaderCylinder CS06000 160VX o 160V 1 1 1 1 1 1 A AA ee Cap Screw I aae A A Cap Screw 63 JPA12125 o NSB2401G195 1 1 1 1 1 1 64 UnloaderPiston 5 CS06400 160D 160 1 1 1 1 1 1 65 O Ring PAam100 JISB2401P100 1 1 1 1 1 1 66 CapSeal 075 CS06600 160 CAP BE 00 1 1 1 1 If 1 67 Push Rod Unloader CS0671 DV 160V 1 1 1 1 TIE Geo Ji EN EA 1681 GuidePin CS068090 gt 1 hi El i 69 LockNu uk o o NG3100 LT L L L L T1 70 LockWasher NG32005 awos Ji J J li J Ji 3 ARI JISBA0IP 111141414141 4 Unloader Cylinder Cover CS07400 160 11605 1_ m 75 Rings 0V PARO smi papa i pi i AR EL Cap Screw 77 IndicatorCam o CSO7700 160VXS 160V ptf e TT indicator Cam csorro isivxtt imi T T m 78 T Bal Bearin
23. 10 A Pags B NF06020 RA 101701 1 01 10 B P ko NFO 1620 2 2 2 11 BearingHead CS01100 320VXD 13208 1 701 1 10 12 Gasket BearingHead 501200 320 1320 00801 1 1 71 13 HangerBot ________NB60016 MI6 1 J 14 SpringPin BNE320600181X 06x18 2 2 2 151 Plig o NF6O RS CT 1 1 ect E 17 dasket D Bearing Cover CS01700 320VD OFT Screw Screw Screw 19 o JAlignmentPin 2016 07 1016x70 20 SpringPin UC 1NE3203 016 03xl6 1 21 1 PI H 1 1 1 RE d 7 22 Balanec PistonCover 1C802200 320 320 J 1 fJ 1 23 o Gasket Balance Piston Cover CS02300 320N 1320 24 erdi Socket Head Cap NB35416 045 M16 x 45 Screw 25 MaleRotor 8 CSO2500 320VS 308 1 26 Female Rotor zg o 25 MaleRotor CS02500 320VM 320M Se 26 FemaleRotor b OME 25 MaleRotor 1C802500 320VL 1320L EN a E 26 Female Rotor gt a gt EE 1 27 MainBearing S CS0270 GRT 28 Side Bearing CS0280 GRT 2 Stop Ring NG11 200 1200 30 Piston o U 1CS03000 320H 31 o Key Balance Piston CS03 100 320 32 Stop Ring NG12 100 3100 33 o Sleeve Balance Piston CS03300 320H 34 Spring Pin NE3206 014 06x14 35 Ringg o PA12 190 JISB2401G190 36 O Ring Spacer 503600 320 37 Stop Ring NG11 200 H200 38 o Th
24. A INC CHEMICAL PROCESS DIVISION Unit 110 6620 McMillan Way Richmond B C V6W 1J7 Canada 1745 Bonhill Road Unit 6 amp 7 Mississauga Ont LST 1C1 Canada 8750 West Bryn Mawr Avenue Suite 190 Chicago IL 60631 U S A 19475 Gramercy Place Torrance CA 90501 U S A 2615 W Casino Road Unit 3D Everett WA 98204 U S A 303 South Broadway Suite 102 Tarrytown New York 10591 U S A 14030 N W 82nd Avenue Miami Lakes FL 33016 U S A 15905 Brookway Drive Unit 4208 Huntersville NC 28078 U S A 3222 Pasadena Freeway Pasadena TX 77503 U S A 16825 IH 35 North Selma TX 78154 U S A 19475 Gramercy Place Torrance CA 90501 U S A TEL 1 604 270 1544 FAX 1 604 270 9870 TEL 1 905 564 0664 FAX 1 905 564 7614 TEL 1 773 516 5070 FAX 1 773 516 5071 TEL 1 310 328 1362 FAX 1 310 782 6759 TEL 1 425 645 9400 FAX 1 425 353 3344 TEL 1 914 301 9770 FAX 1 914 332 0400 TEL 1 305 477 5741 FAX 1 305 477 5681 TEL 1 704 896 3632 FAX 1 704 896 3697 TEL 1 281 447 2599 FAX 1 281 447 6623 TEL 1 210 599 4518 FAX 1 210 599 1778 TEL 1 310 328 6279 FAX 1 310 328 8487 Europe N V MAYEKAWA EUROPE S A MAYEKAWA S L MAYEKAWA MFG CO LTD MOSCOW LIAISON OFFICE MAYEKAWA INTERTECH A G Asia MAYEKAVVA AUSTRALIA PTY LTD P T MYCOM INDONESIA MAYEKAVVA SINGAPORE PTE LTD MYCOM INDUSTRY CO LTD MYCOM INDUSTRY
25. CO LTD CHEMICAL DEPARTMENT MAYEKAWA CHINA INDUSTRIES CO LTD MAYEKAWA CHINA INDUSTRIES CO LTD QINGDAO MAYEKAWA THAILAND CO LTD BANGKOK MAYEKAWA THAILAND CO TRANG TRANG BRANCH MAYEKAWA VIETNAM ONE MEMBER COMPANY LIMITED MAYEKAWA VIETNAM MYCOM KOREA CO LTD HEAD OFFICE Leuvensesteenweg 605 1930 Zaventem Belgium Calle Montevideo 5 Nave 13 Pol Industrial Camporroso 28806 Alcala De Henares Madrid Spain 119049 Moscow Mytnaya St House 3 Flat 54 Russia Rosenbergstrasse 31 CH 6300 Zug Switzerland Unit 2 44 McCauley Street Matraville NSW 2036 Australia Graha Pratama Building 9th Floor JI M T Haryono Kav 15 Jakarta 12810 Indonesia 6 Tagore Lane Singapore 787470 No 2 Shin Jann Road Chien Chen Dist Kaohsiung Taiwan 806 No 2 Shin Jann Road Chien Chen Dist Kaohsiung Taiwan 806 Room 3001 Nanzheng Building No 580 West Nanjing RD Shanghai 200041 China Room 503 Fulin Building No 87 South Fuzhou Road south District Qingdao City 266071 China Bangna Tower Bldg Tower A Bangna Trad RD K M 6 5 Bangkaew Bangplee Samutprakarn 10540 Thailand 1 7 Trang Palian RD Muang Trang 92000 Thailand Room 305 3FL Tuoi Tre Tower 60A Hoang Van Thu Ward 9 Phu Nhuan Dist Ho Chi Minh City Vietnam Juyen Building 2F Seogye Dong 209 Yongsan Ku Seoul 140 710 Republic of Korea TEL 32 2 757 9075 FAX 32 2 757 9023 TEL 34 91 830 0392 F
26. Check the indicator cam groove bearing and pin on the unloader push rod for wear b If refrigerant or oil is found leaking from the indicator replace the V ring To replace the V ring disassemble the seal section of the indicator cam according to the following procedure i On the cylinder side of the unloader cylinder cover there is the bearing gland P N 80 that retains the Indicator cam P N 77 Remove the bearing gland by loosening and removing the hexagon socket head cap screws P N 81 The indicator cam ball bearing P N 78 and stop ring P N 79 will be removed as an assembly ii Remove the stop ring This allows the indicator cam and ball bearing to be detached ii Remove the indicator cam spring retainer P N 84 spring P N 83 and V ring assembly P N 82 from inside the cover c Ifthe V ring portion of the Indicator cam is worn replace the indicator cam 3 14 4 Unloader Piston Unloader Cylinder and Balance Piston Cover Disassembling the Unloader Piston Unloader Cylinder and Balance Piston Cover a Remove the cap nut on the bearing head side of the Vi adiusting rod loosen the lock nut and set the variable Vi auxiliary slide valve to the H port position by turning the Vi adjusting rod counterclockwise until it stops b Screw the eye bolts into the two screw holes in the unloader piston to move the piston toward the indicator to the full load position Unbend the claws of the lock washer on the lock nut that
27. FAX 52 55 5062 0898 MYCOM SCV Series Screvv Compressors Instruction Manual 160VSD 160VMD 160VLD 200VSD 200VMD 200VLD 250VSD 250VMD 7 250VLD 250VLLD 320VSD 7 320VMD 320VLD 160VSG 160VMG 160VLG 200VSG 200VMG 200VLG 250VSG 250VMG 250VLG 250VLLG MAYEKALUA SST 093 00 Nov 2010 No part of this manual may be reproduced without permission from Mayekawa For any questions concerning this manual please contact Moriya Plant Compressor Manufacturing Division Quality Assurance Group Tel 81 297 48 1590 Fax 81 297 48 0632 Mayekavva Mfg Co Ltd reserves the right to change design and specifications in response to technical developments and improvements MAYEK ALU N Corporate office 3 14 15 Botan Koto ku Tokyo 135 8482 Japan Tel 81 3 3642 8181 Fax 81 3 3643 7094 Moriya Plant 2000 Tatsuzawa Moriya shi Ibaraki ken 302 0118 Japan Tel 81 297 48 1361 Fax 81 297 48 5269 URL http www mayekawa com Technical data SST 093 00
28. Gasket Electromizer Flange CR72000 050N MYK50A 1 4 1 1 Hexagon Head Bolt NB15516 045 M16x 45 4 Aguamizer Flange CR74000 032 MYK32A m 5 4 Gasket Aquam zer Flange CR72000 032N MYK32A 1 4 4 4 Hexagon Head Bolt NB15512 040 M12 x 40 4 5 5 1 1 1 1 1 1 5 1 Special Spring Washer ND330 10 MIO 0115 2 1 1 et et et 1 1 1 1 1 1 1 Variable Vi Auxiliary CS28900 250VSD 250VS 1 Slide valve Variable Vi Auxiliary CS28900 250VLD 250VL 1 Slide valve Variable Vi Auxiliary CS28900 250VMD 250VM 1 Slide valve Variable Vi Auxiliary 250VLL 1 Slide valve oo si 232 ass 256 r EE m m b li fal MR mu 35 Fore PaM e pesare 1212121213 1326 Gland O Ring CS32600 250VD__ 2s80v 420 Spacer Unloader Positioning CS42000 250VSD 250V8 1 420 Spacer Unloader Positioning CS42000 250VMD 250VM 1 FO Ring PAll 46 lISB2401P46 12 1432 PAI2 135 llSb24016135 4 1433 TPAID 135 lIS2401G135 4 444 Vi Adiusting Rod Cs44400 250VSD 250V8 11 444 Vi Adjusting Rod Cs44400 250VMD 250VM Lata Vi Adjust as 491 i Laso asi b l il as balli l l 2 O Ring 1 S R N Hexagon Socket Head Cap NB35406 020 M6 x 20 1 1 1 1 1 1 1 1 Screw A ae l Hexagon Socket Head Cap NB35405 010 M5 x
29. N 5 and the main bearings P N 27 in the bearing head P N 11 In addition the thrust bearings P N 38 located outside the main bearings support the thrust loads working on the rotors which result from both the rotation of the rotors and the difference in refrigerant gas pressure that takes place during the compression process The male rotor undergoes a thrust force 1 5 times greater than that on the female rotor as the male rotor receives an extra thrust from being driven by the motor in addition to the thrust from the differential pressure in the refrigerant gas To reduce the load acting on the thrust bearing of the male rotor a hydraulic piston balance piston P N 30 is provided in the suction cover 1 4 2 Sealing of Male Rotor to Prevent Refrigerant Gas Leakage To prevent refrigerant gas leakage various types of mechanical seal are used as the mechanical seal assembly P N 100 for the male rotor which is the compressor s drive shaft For the friction section of any mechanical seal type a combination of carbon and a hard metal or silicon carbide SiC is used to assure adequate sealing and resistance to wear The oil seal P N 50 used as a shaft seal is made of materials that are resistant to various types of refrigerant gas 1 4 3 Capacity Control The unloader slide valve P N 54 which is activated hydraulically via the unloader cylinder P N 60 and the unloader piston P N 64 automatically carries out capacity contro
30. Next select the L M or H port setting whichever is the closest to the calculated Vi value The compressor is set to the H port position before shipment 2 Push the unloader piston P N 64 to move the unloader slide valve to the no load 0 position position shown in Sequence 2 in Fig 2 4 3 From the table of Fig 2 5 Number of Turns of Vi Adjusting Rod for Individual Models determine how many turns the adjusting rod should be rotated in order to set to the port selected in Step 1 above 4 Set the Vi adjusting rod to the selected port as follows SS o 0 x K mz t lt gt N j a 0 ay L Se e I Fig 2 2 Vi Adjusting Rod a Remove the domed cap nut P N 522 at the end of the Vi adjusting rod then loosen the hexagon nut P N 453 used as a lock nut On the compressors produced after March in 2005 a conical spring washer is provided between the hexagon nut and domed cap nut to prevent detachment of the cap nut b Turn the Vi adjusting rod clockwise until it stops The position where the rod stops corresponds to the H port position the setting before shipment Do not turn the rod any further as applying undue force will break the rotation stopping mechanism This position corresponds to that in Sequence 2 in Fig 2 4 c Check the inscribed mark indicated by the white arrow in Fig 2 2 on the Vi adjusting rod which should be used as a reference point
31. Screw score PPE Ee Screw 19 AlignmentPin NE2010 050 10x50 2 2 21 2 2 2 2 2 20 JSpringPin SSCS NEE32OB O1N 93x0 OT PT tT DT L 211 Pag 6 4 a _ RI8__ ET tp aT tp at fa 22 BalancePistonCover______ CS02200 250VX 250V J lJ l l l l l l 23 Gasket Balance Piston Cover CS02300 250N 250 0 u T L T L T L T L ARA e pe l z cal AON Screw 25 MaleRotor 502500 250 5 1250188 1 26 FemaleRotor CS02500250VS 25056 1 25 MaleRotor o CS02500 250vm 25V0M Jif TL 26 Female Rotor 5 BCS02500 24 0VM o 2580Ww L L 25 Male Rotor 5 502500 250 250V T L 26 Female Rotor C 02500 250VL_ 1250010 T T 25 MaleRotor fe SOWELL L l 26 FemaleRoor 6008 7 8 88 8 206 05 L l 27 Main Bearing CS0270FRT 0 25 0 2 2 2 4 2 2 12 4 28 Side Bearing 50280 0125 2 2 2 2 2 2 291 StopRig h9h 9hvV90U NGII 160 Hi o 4 4 4 4 4 4 4 14 30 Piston C 03000 250H_ 250 1 1 1 1 1 1 1 1 31 Key Balance Piston eso3100 250 01250 1 1 1 1 1 1 1 1 32 StopRing o NG 200 S0XV 1 1 1 1 1 1 1 1 33 o Sleeve Balance Piston CS03300 250H_ 250 H__ 1 1 1 1 1 1 1 1 34 Set Screw NA83608020 20 2
32. The unloader indicator assembly is necessary for automatic control of compressor operation It consists of a potentiometer micro switch and micro switch cam There are different types for each of these components and their combination differs according to the control specifications Each number in the following table indicates the required quantity of the corresponding component for one indicator assembly A number in parentheses indicates the quantity of each of the component versions either of which is selectable Control Control 1 Control 2 Control x n mor I for sensing the unloader slide valve position Micro svvitch for sensing the no load 0 position of unloader slide valve Micro switch for sensing the full load 100 position of unloader slide valve Micro switch for sensing the partial load 50 position of unloader slide valve Micro switch for sensing the partial load position of unloader slide valve only for special specification control Micro switch cam 0 100 actuation Micro switch cam 0 50 or 50 100 actuation Micro svvitch cam 7 special control 3 micro svvitches 3 46 Fig 3 125 Standard Unloader Indicator Assembly Components of Unloader Indicator Assembly 126 Screw_____ 4 136 Set screw 3 146 Unloader indicator cover 2 1 1127 Micro switch cam 1 137 Unloader indicator dial 1 1147 Hexagon socket head cap screw 3 128
33. and lighting adequate for performing disassembly and inspection operation Prepare the following items of hand tools materials and equipment e Common hand tools such as a hammer adjustable wrench file scraper sandpaper and scraper in addition to the tools supplied with the compressor see Tools in Chapter 4 e Cleaning solvent light oil or kerosene a container for washing disassembled components rags and a board such as a plywood board on which washed components are placed Fresh oil used during reassembly e Lifting and carrying equipment fir heavy components as necessary e A workbench surface table or stand having a steel plate top with a height appropriate for the work and strength enough to support the compressor s weight 3 2 3 Removing the Compressor from the Base 1 Recovering the Refrigerant Every time before disassembling and inspecting the compressor be sure to confirm that the internal pressure of the compressor has dropped to the ambient air pressure or lower If high pressure refrigerant gas or refrigerant mixed lubrication oil remains inside the compressor a gas and oil under pressure will gush out as soon as a sealed part is loosened and cause injury to the operator When stopped under normal condition the compressor retains in its inside section up to the check valve a pressure as high as the oil separator pressure Therefore it is essential to lower the compressor s internal pressure to a level eq
34. auxiliary slide valve 2 4 2 How to Adjust the Vi Never perform Vi adjustments while the compressor is in operation Perform Vi adjustments only after stopping the compressor Because the rotary shafts are near the Vi adjustment location there is an increased risk of personal injury or death as clothing can be caught in rotating shafts or tools may get in touch with them Be sure to turn off both the compressor motor main power and the control power after following the pre established compressor stopping procedure In addition take all necessary measures to prevent any persons other than the person performing the Vi adjustment from accidentally turning on the power supplies Failure to do so will result in a serious accident 2 3 Chapter 2 Essential Points for Operation s When turning on or off the electric power supplies be sufficiently careful to avoid electric shock CAUTION e Do not operate the compressor with the Vi at any other setting than the L M or H port setting NOTE e The P N numbers in the following procedure correspond to the part numbers in 1 6 1 Components Drawings and 1 6 2 Parts Lists e Read the instructions in the following procedure while referring to Fig 2 4 1 First determine the expected operating condition of the system and work out the Vi value under the condition thus determined use the formula shown in 1 3 1 What Is the Internal Volume Ratio Vi for the calculation
35. bearing if a guide rod is attached to the pin as indicated by the arrow in Fig 3 78 Guide rod Fig 3 78 Positioning the Side Bearing Fig 3 79 Installing the Side Bearings b Secure the side bearing by installing the stop ring c Attach the O ring P N 9 in the hole in the suction cover Then install the O ring gland P N 326 through which the unloader push rod is to be installed Fig 3 80 O Ring P N 9 Installed in Fig 3 81 O Ring and O Ring Gland P N 326 Suction Cover 3 32 d Install the balance piston components into the suction cover as follows Install the following parts in the order of mention inner stop ring P N 37 O ring spacer P N 36 O ring P N 35 balance piston sleeve P N 33 and outer stop ring As the outer stop ring installed last is pushed outward by the O ring you must push it to fit it in its groove When installing the balance piston sleeve during the above operation block the sleeve against rotation using either of the following methods see Figs 3 34 to 3 36 in 3 2 5 5 Type 1 160 250VSD VMD VLD VLLD Screw one set screw P N 34 into the suction cover from the male rotor side and screw the other set screw into the suction cover from the female rotor side Type 2 320VSD VMD VLD Fit the pin provided on the outside diameter of the balance piston sleeve into the groove in the suction cover e Turn the Vi adjusting rod counterclock
36. is securing the piston to the push rod see Fig 3 26 c Loosen the lock nut P N 69 using the lock nut wrench separately available tool d Remove the unloader piston from the push rod using the eye bolts K Ta Eye bot Z Fig 3 26 Unbending the Claws of Lock Washer Fig 3 27 Removing the Unloader Piston e The unloader cylinder is fitted to the balance piston cover with two short hexagon socket head cap screws P N 61 and to the suction cover with six long hexagon socket head cap screws P N 62 Do not separate the balance piston cover and the unloader cylinder unless it is absolutely necessary to do so However if the interval after the previous inspection is relatively long replace O ring P N 63 after separating the balance piston cover and unloader cylinder by removing the two short hexagon socket head cap screws f Remove the screws on the balance piston cover After placing a container under the cover to catch oil flowing out pull the whole cover toward you to remove the unloader cylinder and balance piston cover from the suction cover Inspecting the Unloader Piston Unloader Cylinder and Balance Piston Cover a Check the cap seal P N 66 on the periphery of the unloader piston Replace the seal if it is damaged deformed or worn Always replace the O ring b If the inner wall of the cylinder is scratched or contaminated with oil deposits polish the wall with fine emery paper finer than 400 and then
37. not avoided could result in death or serious 4 WARNING G Indicates a hazardous situation which if not avoided will or could result in minor or A CAUTION moderate injury Indicates a hazardous situation which if not avoided will or could result in damage to the product or other property CAUTION The safety instructions in this manual are not exhaustive There may be other safety precautions to be observed that vary from user to user It is your responsibility to establish a safety management system most appropriate for your particular use of the product VVarranty Notice VVarranty Mayekawa will repair this product or replace its components free of charge in the case of malfunctions of or damage to the product due to defects in design or vvorkmanship during normal use of the product under conditions not contradicting to the specifications and instructions Mayekavva has given by any means including this manual provided the malfunctions or damage in question occurs vvithin the vvarranty period indicated belovv The vvarranty period shall be 12 months from the date of shipment of the product from the factory Mayekawa will not be liable for any personal or property damages consequential to any malfunction of or damage to this product including but not limited to any loss of business or profits Disclaimer of Warranty Despite the warranty clauses mentioned above Mayekawa shall be exempted from offering the warranty for malfunc
38. oil temperature 3060080410 0202272 9 8 Maximum male rotor speed 4 500 rpm 3 600 rom for 250VLLD VLLG and 320VSD VMD VLD Minimum male rotor speed 1 450 rom 11 Refrigerant NH3 HFC etc Ps suction pressure 0 6 7 in Pd discharge pressure e Prolonged 30 or lower part load operation may cause noise and vibration and therefore should be avoided 2 1 Chapter 2 Essential Points for Operation 2 3 Connecting Ports on Compressor Fig 2 1 shows the connecting port locations of the compressor EM UU Connecting port II for liquid injection amp Electromizer connecting port Connecting port 1 for liquid injection 9 return port plug Oil supply port for female rotor side bearing Control wiring connector 4 1 Discharge gas outlet Connecting port for unloader control oil for 100 load 5 Connecting port Il for unloader control oil 12 Oil drain port for 0 load 6 Suction gas inlet Connecting port for oil injection Lubrication oil main supply port journal C Fig 2 1 Connecting Ports of Compressor 2 2 2 4 Adjustment of Vi 2 4 1 Considerations to Take When Using Vi Adjusting Mechanism Change the Vi setting only when the application of the SCV Series Screw Compressor is significantly changed using the examples shown below as a guideline Changes in operating condition experienced in daily operation have no significant influence on the brake horse
39. piston and the unloader push rod will engage each other while the unloader cylinder is being pushed into the suction cover see Fig 3 111 Fasten the balance piston cover temporarily to the suction cover using two or three hexagon socket head cap screws see Fig 3 112 Secure the unloader piston to the unloader push rod with the lock washer and lock nut Bend the claw of the lock washer 4 Mr Fig 3 112 Temporarily Installing the Balance Fig 113 Securing the Unloader Cylinder Piston Cover 3 42 d Finally secure the balance piston cover and unloader cylinder to the suction cover with the hexagon socket head cap screws see Fig 3 113 e By moving the unloader piston using the eye bolts screwed in its threaded holes check that the unloader slide valve moves smoothly 8 Unloader Cylinder Cover When the indicator cam s seal portion in the unloader cylinder cover has been disassembled reassemble the components according to the following procedure while referring to Fig 3 114 a Fit the ball bearing on the indicator cam s shaft see Fig 3 115 When fitting the bearing onto the shaft push the inner race of the bearing Push the bearing to the stepped portion of the indicator cam and retain the bearing with the stop ring b Fit the V ring set coated with oil into the unloader cylinder cover One V ring of the set is made of rubber for improved sealing performance Fit the V section end into the unloader
40. result in leakage see Fig 3 121 g Fit the mating ring s O ring P N 103 and mating ring P N 101 to the seal cover see Fig 3 122 Fit the gasket to the seal cover while aligning the oil holes in both parts then install the seal cover while aligning its oil hole with that in the bearing cover and also keeping the seal cover at right angles with the shaft When the seal cover is pushed to a midway point its surface comes in contact with that of the mating ring The seal cover will receive the repelling force from the seal spring while it is being pushed against the bearing cover Keep the seal cover strongly pushed against the bearing cover and fasten the seal cover by tightening the diagonally opposite two hexagon socket head cap screws see Fig 3 123 After fastening the bearing cover until there is no clearance around its gasket surface tighten all the remaining hexagon socket head cap screws see Fig 3 124 Fig 3 121 Installing the Mechanical Seal Assembly Fig 3 122 Fitting the Mating Ring into Seal Cover 160 Models Do not forget to plug the hole 3 45 Chapter 3 Maintenance Fig 3 123 Installing the Seal Cover Fig 3 124 Fastening the Seal Cover 3 4 Disassembly and Reassembly of Unloader Indicator Assembly This section describes the instructions to be followed when disassembling inspecting reassembling and adjusting the unloader indicator assembly 3 4 1 Components of Unloader Indicator Assembly
41. thoroughly wash it clean c Replace the O ring P N 73 at the connection between the unloader push rod and unloader piston 3 15 Chapter 3 Maintenance Fig 3 29 O Ring on Unloader Push Rod Fig 3 30 Exploded Vievv of Balance Piston Disassembling the Balance Piston and Balance Piston Sleeve a Remove the stop ring P N 37 retaining the balance piston P N 30 on the shaft using pliers b Screw the eye bolts into the hole in the balance piston and pull out the piston in parallel with the axis of the shaft see Fig 3 32 Leave the balance piston key P N 31 fitted in the keyvvay of the rotor shaft Fig 3 31 Removing the Balance Piston Stop Ring 3 16 c The balance piston sleeve is locked by either of the following methods Type 1 Locked by a screw at the notch in the balance piston sleeve 160 250VSD VMD VLD VLLD Type 2 Locked by a spring pin by driving the pin into the sleeve and fitting it into the suction cover groove 320VSD VMD VLD Fig 3 35 Loosening the Balance Piston Locking Screvv 3 17 Chapter 3 Maintenance Fig 3 36 Spring Pin for Locking the Sleeve 320V Fig 3 37 Removing the Stop Ring for Balance Piston Sleeve d With the balance piston sleeve P N 33 locked using the Type 1 method the sleeve has a notch using which it is locked by screwing two hexagon socket head cap screws into a threaded hole one from the notch side male rotor side and the other from the opposi
42. 0 200 200 T T l l l l 251 o FlectromizerFlange CR74000 032 MYK32A 1 1 1 1 1 1 252 Gasket Electromizer Flange CR72000 032N 1 1 1 L L T 253 HexagonHeadBolt B NB15512 0400 o M12x40 __4 4 4 4 254 AquamizerFlange h CR74000 025 MYK25A 1 1 1 255 Gasket Aquamizer Flange CR72000 025N____ MYK2SA _ 1 1 1 256 HexagonHeadBoltt________ NBIS512 035____ MI2x35__ 4 4 4 267 o Special Spring ND330 08 MR 5 5 5 72 ci O Slide Valve 289 Variable Vi Auxiliary CS28900 200VMD 200VM Slide Valve SAA A fs es E io E A 289 Variable Vi Auxiliary CS28900 200VLD 200VL Slide Valve BE s 325 O Ring 11 04 4 SB2401P40 2 2 2 2 326 1 Gland O Ring CS32600 200VD 2X2 1 1 1 1 420 Spacer Unload Position C842000 200VSD 200V8 Tr T TT 420 1 Spacer Unload Position oo CS42000 200VMD 1200VMF 1 J 4211 1 0 Ring PAII040 ISB2401P40 2 4821 0 Ring O P amp 9 gt WG 4 4 4 4 4 4 4331 O Rig___ PA amp O WG 4 4 4 4 4 4 4441 ViAdjustingRod 1C844400 200VSD 200 5696 7017720 111 444 1 o ViAdiustingRod 1C844400 200V MD 1200V MF 1 L 444 Vi Adjusting Rod 1C844400 200VLD 20004 01 11 J 446 Vi S
43. 0 260 39 5 39 5 15 160 251 5 248 199 510 260 250VS 70 30 320 34 5 34 5 15 198 307 375 331 640 320 105 40 400 55 5 255 376 480 422 780 380 Model A ME 1 de ee ee Sey 60VS 140 102 5 187 5 162 5 132 5 EH 5 EZ 9 241 Ii 296 5 215 4 5 349 5 5 ODODO DODONA 431 394 5 Weight table Weight kg 160VSD 160VSG 350 360 650 680 1 39 Chapter 2 Essential Points for Operation 2 1 General This chapter describes the instructions that are essential to be followed when operating the MYCOM SCV Series Screw Compressors including the procedure for adjusting the Vi and recommendations for the lubricant to be used 2 2 Points to Be Observed When Operating the Compressor e The SCV Series Screw Compressors should be operated in the conditions within the limits indicated in Table 2 1 As to the oil supply pressure item No 5 in the table the pressures for the pump pressurized supply system should be applied to the capacity control system hydraulic pressure for controlling the unloader slide valve Table 2 1 Operational Limits for SCV Series Screw Compressors Maximum discharge pressure 1 96 MPaG 1 37 MPaG for 250VLL 0 589MPas 8080808028 2 0 59 MPaG 0 080 MPaG suction and discharge pressures Oil supply pressure Differential pressure supply system system Pd discharge pressure Pd 0 049 MPaG i 30 C N Minimum supply
44. 0 ERT 1200 2 2 29 StopRing______ NGIHIBO 3 3 4 4 4 4 4 30 Balance Piston 1C803000 200H 12000 1 1 1 1 1 NE EE e L 2 La 31 Balance Piston 503100 201 1200 32 Stop Ring 77 NG206 1865 33 Sleeve Balance Piston o CS03300 200H 1200 34 Set Serev UC NA83608015 1M8x15 2 35 O Ring oo PAI 120 NSB2401P120 1 36 O Ring Spacer CSO3600200_ 1200 J 1 1 37 Stop Ring NGIHI3O 0H30 2 2 2 38 ThrustBearing 1C803800 200P 173138 2 2 2 39 LockNut 0 0331030 1413 2 2 2 40 Lock Washer 1NG320013 JAW 2 2 2 ae eC 161 gt gt 1 2 2 21 77 4 4 4 4 E AE He EEE EE A 25 10 NM E 111 eek m s EA Pe s ee 2 3 Lee ee gt 1 23 Chapter 1 Principle of Operation and Construction a O IA Outer Race 42 Spacer Thrust Bearing CS04200 200 200 2 2 2 2 2 gt AA 1151155000 A ps Beninge Gd 45 HexagonHeadBolt NB15512 035 12 35 46 Conical Spring VVasher M12 MH ANN vvasher 48 48 Retainer Oil Seal_ S04800 200V_ 200V BOSTYPE 1 1 1 1 1 i 49 O Rig 0080 paris G TE N r N N 50 OilSeal 7 8CS05010 200VD SAIJ65x85x12 1 1 1 1 1 1 51 Beal Cover 9 CS051000 200BBS 12008 1 1 1 1 1 1 52 Gasket SealCover 1
45. 0 x 55 nri eE EKA el el 60 Unloader Cylinder 1 506000 250 250V uu Se at Nissa ns LT Screw S seen mem M M MMN Screw 63 PAI2190 JISB201GI90 L L L L L L L L Unloader Piston 5 1 6S06400 25605m 2504 0 0 11 11717117171 64 65 s l E IS S4101 P feve PE T Slide Valve 71 To FE T Slide Valve 68 GuidePin U 1CS06809 05 05x12 pt parfait a papaya O T sir ram las A 70 Lock VVasher 7 NG32 008 111 FO Ring pais msm a 14 UnloaderCylinder Cover ___ CS07400 250 1 H 75 O Ring PAZI 5 240101 70 1 1 1 1 76 Hexagon Socket Head Cap NB35412 030 MI x 30 Screw L IT MH nn 77 IndicatorCam U 1C807700 250VX8 250VS Jif EA 77 Cam CS07700 250VXML _ 250VL VM 1 1 1 ila li 78 Bearing 1C807800 200 6000 lili 1 1 1 1 1 S AHHH HH H 80 BearingGland______ CSOS000200 1200 IA yt pt 81 Hexagon Socket Head Cap NB35406 015 da x 15 Screw 1 27 Chapter 1 Principle of Operation and Construction 82 V ring 7 508200 200 20x10x12 laet 1821 Iset Iset Iset Iset Iset Iset 831 Spring 508300 200 120004 alal ifa la Ji 84 Retainer Indicator Cam Spring CS08400 200 200 ft tT EP a a 91 ShaftKey CS09100 25 0 J250 ____ 1 1 11 1 1 1 1 92 Suctio
46. 10 4 41 41 14 T A 4 Eu EN m m Vi Adjusting Rod CS44400 250VLD 250VL eee az DO BE Dal Screw 1 28 99 P ET OTS Rio n 522 ibomed Cap Nut_NC921 36_ 3TypeM36__ li 523 O Ring ___ PA11040 oc JISB2401P40 711111 1528 Sleeve OilSeal__________ CS52800 250VD 250V ______1 1 1 529 SetScrew_____ NA8S3606 008 M6x8 20053 2 2 2 533 Spring Washer ND330 06 M6 _1 1 1 605 Plu NF06 025 R l l 607 A Plug NF06 004 14 _1 1 1 607 B Plug 77 NF06 004 RIA Jijiji 680 A Conical Spring MBG 1 1 1 680 B Conical Spring Washer M36 1 1 1 EE s gl li 12121212421 MH nsn s n EL b Mu EE esi 1111 1 29 Chapter 1 Principle of Operation and Construction 4 320VSD 320VMD 320VLD 1 Main Rotor Casing o CS00100320VXS 320V8 0171771001 Main Rotor Casing A i i 1 Main Rotor Casing 4500100 320 320V Hexagon Socket Head Cap NB35424 080 M24 x 80 a e 3 Alignment Pin 8TNE2025 080 1025x0 401 4 4 4 Hanger Bolt 98BNB60030 IMB 1 2 2 2 5 Suction Cover CS00500 320VXD 320V 01 1I 6 Gasket Suction Cover______CS00600 320VD____ 320V ____ 1 27 HangerBolt 600 6 MIG 1 2 20712 28 SpringPin BNE3206 0018 06x18 J 2 2 2 2 9 ORing PA11058 YISB2401P8 1 1 0
47. 2 2 2 2 2 9 1 0 Ring PAI2060 HSB2401G600 1 1 1 1 1 1 PIO DA iPug N ET E 10 B P TNF06008 R14 10 C Pugs o NFo6eois RID 10 D Plg B NF06015 0 RE 1 11 BearingHead CS01100 200VXD__ 200V 1 11 BearingHead CS01100 200VXG 0 200V G E ME CEA 12 o Gasket BearingHead 501200 2000 200 13 HangerBot _ NB60012___MI2 14 SpringPin NE3206012 __ 06x12__ 16 Bearing Cover CS01600 200VXD 200v 16 Bearing Cover CS01600 200VXG 200V G 17 Gasket D Bearing Cover CS01700 200VD 200V 0071 17 Gasket G Bearing Cover CS01700 200VG 1200V 6 177 un Screw vir Sasa hes Jue Screw 2775077 e 15 Screw 19 AlignmentPin 1NB2010 0500 10x50 0721212 20 Spring Pin Ne303 010 esto zii ME O aN 22_ Balance Piston Cover__ 802200 200VX_ 200V 23 TdGasket Balance Piston Cover CS02300 200N 12007 71711 111111 11 24 1 Socket Head NB35412 030 M12 x 30 11 11 11 11 Cap Screw 25 MaleRotor CSO2500 200VS 200 56 1 emele Rotor mvs a gt 25 MaleRotor CSO2500200VM_ 200VM 1 J Tif 26 Female Rotor 2 200VM Jary L 25 MaleRotor CS02500 200yL_ 200V 01 11 J 26 Female Rotor 1 7 Reve l 27 Main Bearing 1 50270 200 2 2 28 Side Bearing 1C8028
48. 2 2 2 2 2 2 2 35 O Ring_______ PAII 150 JISB2401P150 T TT T L L T LT 1 26 CFO Rag Spacer is T Tilli Trlilil 36 Ring Spacer SOE J ili 37 StopRing NGI116 o HG 2 2 2 2 2 2 2 2 38 ThrustBearing 1C803800 250P 17317B 2set 2set 2set 2set 2set 2set 2set 2set flock Nut__ING3I O17 ANI 02221212 21212 40 Lock Washer__ No32 017_JAWI7___ 21212 42 Spacer Thrust Bearing CS04200 250 250777 Alignment s Bearing T 212 2 45 O Hexagon Head Bolt NB15516 045 M16 x 45 46 Conical Spring VVasher 05 hexagon head bolt lock vvasher dai F 250 48 Retainer Oil Seal CS04800 250VD 250V BBSE BBS III BOS 2121212 x PPO Ring 3 SBMO 1111 50 Oil Seal CS05010 250VD SAIJ75 x 100 x 13 75x 100 x 13 EIE TTO 52 Gasket Seal Cover CS05200 250N 250 TT tft Tt tft 1 53 eon Socket Head Cap NB35412 030 x 30 Screw 54 Unloader Slide Valve 505400 250 50 250 56 56 tninas Side Vale y on Iii 54 Unloader Slide Valve 1 505400 250 25OVM ili fif 54 UnloaderSlide Valve grooved 25VWM 1 1 54 Unloader Slide Valve CS05400 250VLD 250V J Jif E toner Side a ve grooved poo LI LIL 54 Unloader Slide Valve 1 EXA tf fp 54 Unloader Slide Valve grooved fee 58 Hexagon Socket Head Cap NB35410 055 M1
49. 20V M36 x P3 5 mm Number of turns x Pitch mm Displacement distance of variable Vi auxiliary slide valve 2 Chapter 2 Essential Points for Operation 2 5 Lubrication Oil Selecting appropriate lubrication oil and properly controlling its condition is essential for proper operation of the compressor This section describes the points you should consider when selecting and handling lubrication oil 2 5 1 Selection of Lubrication Oil Selection of the lubrication oil should depend on the type of the refrigerant the type of the evaporator used with the compressor and the conditions under which the compressor is operated Also to be considered when selecting lubrication oil are the properties of the oil that include not only the viscosity but also such characteristics as solubility in refrigerant separability from refrigerant low temperature fluidity high temperature thermal stability etc As there are so many factors to consider it is most advisable to ask any of our offices or sales service centers about selection of lubrication oil They can suggest suitable oil brands for your specific application of the compressor Lubrication oil used for compressors must have a viscosity appropriate for lubricating the bearings and other components in the compressors The viscosity to be considered in this case should be the viscosity the oil shows at the oil inlet of the compressor The viscosity of the lubrication oil significantly changes de
50. 250VLG 250VLLG 2 320VSD 320VMD and 320VLD 1 160VSD 160VMD 160VLD 160VSG 160VMG 160VLG 200VSD 200VMD 200VLD 200VSG 200VMG 200VLG 250VSD 250VMD 250VLD 250VLLD 250VSG 250VMG 250VLG 250VLLG Use the part numbers in the drawing as keys to the parts lists in section 1 6 2 Chapter 1 Principle of Operation and Construction 320VSD 320VMD and 320VLD 2 Use the part numbers in the dravving as keys to the parts lists in section 1 6 2 1 18 1 6 2 Parts Lists This section shows the parts lists for the following models 1 2 3 4 160VSD 160VMD 160VLD 160VSG 160VMG 160VLG 200VSD 200VMD 200VLD 200VSG 200VMG 200VLG 250VSD 250VMD 250VLD 250VLLD 250VSG 250VMG 250VLG 250VLLG 320VSD 320VMD 320VLD NOTE The code numbers indicated in each list are those updated in and after December 2009 Chapter 1 Principle of Operation and Construction 1 160VSD 160VMD 160VLD 160VSG 160VMG 160VLG 1 Main Rotor Casing 7C8S00100 160VXS 1160V88 J1 f Jif 1_ Main Rotor Casing C800100 160VXM 160VM ft ff 0 I Main Rotor Casing _ CSOOI00 160VXL I60VI e 1111 11 Hexagon Socket Head NB35412 045 Mi x 45 52 52 52 52 52 3 Cap Screw 3 AlignmentPin NE2013 0400 13x40 4 4 4 4 4 4 4 HangerBolt NBOOO 20 M20 J1 1 1 1 1 1 5 SuctionCover CS00500 160VX l60v __ 1 1 1 1 1 11 6 o GasketSuctio
51. 3 7 Chapter 3 Maintenance Stationary Rotating Set screvv O ring Drive pin Previously designated as Carbon Oil seal sleeve Seal collar set screw Mating ring Seal ring Seal collar 111 108 528 529 144 50 O ring D E Su o 5 x O 20 z O S SOLES i 9999 E A Mi L WEN T R DES Fig 3 11 BOS Type Mechanical Seal Assembly 3 8 000008 Mating ring Insert lock pin O ring Seal collar Seal collar set screw O ring Oil seal sleeve Set screvv O ring Retainer oil seal O ring Oil seal Stationary rings Rotating rings Fig 3 12 BBS III Type Mechanical Seal Assembly 3 9 Chapter 3 Maintenance il Fi j j d y y i j b 101 1 Fi Fi 771 pn a F fi H Fi EOS L 4 i S mn Pa H an y A Part Name 101 3 aie 57 Oil seal sleeve Set screvv O ring Retainer oil seal O ring Oil seal Spring pin Fig 3 13 BBSE Type Mechanical Seal Assembly Inspecting the Mechanical Seal Assembly a Inspect the friction surfaces of the mating and seal rings If the mating and seal rings have evenly bright friction surfaces they can be reused If the rings show irregular or scratched surfaces they will cause leaks and should be replaced with new o
52. 5 0 59 320V 10 17 0 21 10 20 0 24 10 23 0 27 10 26 0 30 10 70 0 76 0 73 0 79 10 77 0 83 10 81 0 87 Mechanical Seal Assembiy P N 100 160V BOS T1 200 a BBSE BBS li ESSE OS E1 Bolt Sizes quantity in parentheses 160V 200V 250V 320V Hexagon socket head cap Tar 52 M16x50 50 M20x60 44 M24x80 52 Screw 18 1 Bearing cover Hexagon socket head cap M12x40 19 D 1 M16x50 15 D M16x50 18 D M20x70 19 screw M12x40 2 Al M16x50 1 JE M16x50 2 ar Hexagon socket head cap CON M20x120 screw 18 3 Bearing cover Hexagon socket head cap M16x65 6 M16x70 5 D M20x120 6 screw M16x70 6 G Balance piston cover Hexagon socket head cap M10x25 11 M12x30 11 M12x30 11 M16x45 11 Screw Balance piston sleeve M6x15 2 M8x15 2 M8x20 2 Thrust bearing gland Hexagon head bolt UT i si ae 53 Seal cover Hexagon socket head cap 8 25 8 x 10 258 12 308 M16x40 Screw Si Unloader push rod Hexagon socket head cap M6x30 5 M8x45 5 M10x55 5 M12x55 5 screw k Unloader eylinder Hexagon socket head cap M10x25 2 M12x30 2 M16x40 2 M20x50 2 Screw Unloader cylinder Hexagon socket head cap M10x65 6 M12x75 6 M16x90 6 M20x110 6 screw Unloader cylinder Hexagon socket head cap M8x25 8 M10x25 8 M12x30 8 M16x40 8 cover screw Bearing gland Hexagon socket head cap M6x15 3 M6x15 3 M6x15 3 M6x15 3 screw Suc
53. 8 Tokai Branch Office 1 15 36 Takamatsu Suruga ku Shizuoka shi Shizuoka TEL 81 54 236 5350 ken 422 8034 FAX 81 54 236 5355 Chubu Branch Office 2 9 6 Marunouchi Naka ku Nagoya shi Aichi ken 460 TEL 81 52 218 3307 0002 FAX 81 52 218 3308 Kansai Branch Office 1 4 27 Ebie Fukushima ku Osaka shi Osaka 553 0001 TEL 81 6 4795 6000 FAX 81 6 4795 6033 Chugoku Branch 2 3 40 Takayadai Higashihiroshima shi Hiroshima ken TEL 81 82 491 1830 Office 739 2117 FAX 81 82 491 1838 Shikoku Branch Office 410 1 Otakamimachi Takamatsu shi Kagawa ken 761 TEL 81 87 868 3400 8074 FAX 81 87 868 3399 Kyushu Branch Office Fukuoka Fujiland Bdg 10F 2 3 TEL 81 92 262 0016 Nakasu Nakanoshimamachi Hakata ku Fukuoka shi FAX 81 92 262 0115 Fukuoka ken 810 0802 Overseas North America MYCOM CANADA LTD VANCOUVER OFFICE MYCOM CANADA LTD TORONTO OFFICE MAYEKAVVA U S A INC HEAD OFFICE MAYEKAVVA U S A INC INDUSTRIAL REFRIGERATION DIVISION LA OFFICE PLANT MAYEKAWA U S A INC INDUSTRIAL REFRIGERATION DIVISION SEATTLE OFFICE MAYEKAWA U S A INC INDUSTRIAL REFRIGERATION DIVISION NY OFFICE MAYEKAWA U S A INC INDUSTRIAL REFRIGERATION DIVISION MIAMI OFFICE MAYEKAWA U S A INC INDUSTRIAL REFRIGERATION DIVISION CHARLOTTE OFFICE MAYEKAWA U S A INC INDUSTRIAL REFRIGERATION DIVISION HUSTON OFFICE MAYEKAWA U S A INC MANUFACTURING DIVISION MAYEKAWA U S
54. AX 34 91 830 0397 TEL 7 499 230 01 76 FAX 7 499 230 21 12 TEL 41 41 726 8626 FAX 41 41 726 8620 TEL 61 2 9695 7000 FAX 61 2 9695 7001 TEL 62 21 8370 9484 FAX 62 21 8370 9483 TEL 65 6451 1565 FAX 65 6451 4932 TEL 886 7 821 0886 FAX 886 7 821 4688 TEL 886 7 821 7709 FAX 886 7 821 9019 TEL 86 21 5234 1988 FAX 86 21 5234 1788 TEL 86 532 8602 6169 FAX 86 532 8602 6269 TEL 66 2 751 9610 FAX 66 2 751 9565 TEL 66 75 224 784 FAX 66 75 224 351 TEL 84 8 3997 5284 FAX 84 8 3997 5287 TEL 82 2 796 1766 FAX 82 2 798 7715 MYCOM KOREA CO LTD CHANGWON FACTORY MYCOM KOREA CO LTD PUSAN BRANCH MAYEKAWA INDIA PVT LTD GURGAON OFFICE Latin America MYCOM PERU S A C MAYEKAWA CHILE S A C el SANTIAGO OFFICE MAYEKAWA DO BRASIL LTDA SAO PAULO MAYEKAWA DO BRASIL LTDA RIO DE JANEIRO BRANCH MAYEKAWA DO BRASIL LTDA MACAE MYCOM CENTROAMERICA S A MYCOM VENEZUELA SALES amp SERVICES C A CARACAS OFFICE MYCOM VENEZUELA SALES 8 SERVICE C A MARACAY OFFICE MAYEKAWA DE MEXICO S A DE C V CUERNAVACA OFFICE MAYEKAWA DE MEXICO S A DE C V MEXICO CITY OFFICE Palyong Dong 24 20 Uichang ku Changwon Kyungsangnam Do 641847 Republic of Korea Tong Young Su San 6F 763 20 Kamcheon Dong Saha Ku Pusan 604 806 Republic of Korea 309 Centrum Plaza Golf Course Road Sector 53 Gurgaon Haryana 122011
55. CS05200 200N 200 1 1 1 1 1 1 Id Toys Mie T 1111 Cap Screvv 54 Unloader Slide Valve 1C805400 200V8SD 2000 56 I ender Sid Vane s0s400 200v pov T pp 54 Unloader Slide Valve CS05400 200VLD 1200017 7 71 J I Ji AAN A AA Cap Screw 60 o J nladerCylinder CS06000 200VX o 200 459 1 1 1 1 1 A Ap Cap Screw SL RI O et 17110 17171 Cap Screvv 631 O Ring_ 12 15 JISB2401GIS0 1 1 1 1 1 1 61 tnf ader Piston esoo aoo oo iI I Ti i io EH A 111 66 CapSel O 506600 200 1 1_ 67 Push Rod Unloader CS0671 EV 00 Slide Valve 68 GuidePin 1CS06809 05 5 2 0 tt DI 769 le NG 1 007 ano TTT Tl i pt 70 1 Lock Washer 1NG32 007 AW7 1 1 1 1 1 1 73 1 O Ring 7 PA12030 VISB2401330 1 1 1 1 1 1 4 Unloader Cylinder Cover _ 807400 200 1 1 1 751 1 0 Ring PAI2 1353 VISB2401G 35 1 1 1 1 11 76 Hexagon Socket Head NB35410 025 m x 25 Cap Screw 77 IndicatorCam CS07700 200VXS 20V88 1 1f TT indicator Cam CS07700 20VxML 20vM 30v T T T 78 BallBearing 8 S07800 200 0 600 1 1 1 1 1 1 pi de rr gt AE ts 80 BearingGland 508000 200 200 1 1 1 1 1 S ust anca e J HH Screw 821 V ring S08200 20B 20x10x12_ 1 1 1 1
56. KS di Li Supply Flange 217 Hexagon Head Bolt NB14012 040 M1I2x40 1 2 Hanae nisan Oo Samy E A 219 Gasket Oil Injection Flange 1 CR72000 025N MYK25SA 1 1 1I 220 Hexagon Head Bolt o 035 M12 x 35 mes A AL A 235 O Spacer Discharge Flange NA 1 236 Gasket Discharge CS23600 320N Flange Spacer IBI IBI 237 Torsional Slip Washer CS23700 320 Bu 06 A 250 Thrust Washer 525000 320 251 Electromizer Flange CR74000 080 MYK80A 252 Gasket Electromizer Flange CR72000 080N MYK80A 253 o Hexagon Head Bolt NB15520 055 M20 x 55 254 Aguamizer Flange CS71400 050 MYK50A 255 o Gasket Aquamizer Flange 1 CR72000 050N MYK50A 256 o Hexagon Head Bolt NB15516 045 M16 x 45 267 O Special Spring Washer ND330 12 M 5 5 5 289 Variable Vi Auxiliary Slide CS28900 320VSD 320VSD SREE ar m TT T IEA 289 Variable Vi Auxiliary Slide CS28900 320VMD 320VMD F a AAA AA 0700011 R o LL Valve 326 __ Gland O Ring 200 space nlemi olan Cotone 420 Unload 542000 320 320 420 o Spacer Unload Position oo CS42000 320V D 320V1 I 4211 0 Ring UC 2 11 058 9 2401 58 2 2021 2 4321 1 0 Ring UC PAI2165 V SB2401G165 4 J 4 4 433 1 0 Ring UC PA12 165 JHSB2401G16 4 1 4 J 4
57. Set sc screw 1 138 Screv Screw 2 MB 129 Potentiometer 27 Fig 3 126 Exploded View of Unloader Indicator Assembly 3 47 Chapter 3 Maintenance if DI dt T L R 55 IW AE 2 m 48 seniz een SS Plelelelelelelek z x DSDOIZJOD AA Ly S OOO 20 My EEN y N f bh siz ae z T AO e CD Geo eee S 2 Fig 3 127 Sectional View of Unloader Indicator Assembly 3 48 3 4 2 Disassembly a Remove the screw P N 140 securing the pointer PN139 to the shaft b Remove the screws P N 138 securing the unloader indicator dial P N 137 to the dial supports c The potentiometer mounting plate P N 130 is fitted between the dial plate supports 1 P N 134 and dial plate supports 2 P N 135 Loosen and remove the supports 2 by turning them counterclockwise while holding the supports 1 d When the right and left supports are removed the potentiometer P N 129 can be removed together with the mounting plate e The potentiometer is secured to the mounting plate with three screws f The micro switch P N 125 is secured with two long screws P N 126 Loosen these screws to remove the micro switch g The micro switch on the right is for sensing the no load 0 position and the micro switch on the left is for sensing the full load 100
58. UC NG31 010 ANIO 70 Lack Washer NG32 010 AW10 B 1 0 Ring 11 044 JISB2401P44 74 Unloader Cylinder Cover CS07400 320 75 O Ring PA12210 rap 76 Hexagon Socket Head Cap NB35416 040 M16 x 40 Screw 77 IndicatorCam 1CS07700 320 8 1320VS 77 IndicatorCam CS07700 320V M _ 320VM AAA AA 77 mndicator Cam YU 1CS07700 320V7L 320VI ro 78 Ball Bearing CS07800 200 6000 79 Ring NG12 010 80 Bearing Gland CS08000 200 200L Foce cl 9 81 Hexagon Socket Head Cap NB35406 015 M x 15 Screw 82 V ring 508200 200 20 x 10x 12 230 8 Spring 7 CS08300 200 200L 84 Retainer Indicator Cam Spring CS08400 200 200L 91 ShaftKey CS09100 320 92 Suction Flange CS71400 P350 MYK350A 93 Gasket Suction Flange CS09300 320N MYK350A 94 o Hexagon Head Bolt NB12024 075 M24 x 75 ETS AE 95 Discharge Flange CS71400 P200 MYK200A 95 Discharge Flange CS71400 P200CD 1 MYK200CD 96 G Discharge Flange CR72000 200N MYK200A 97 o Hexagon Head Bolt NB12020 055 M20 x 55 100 Mechanical Seal Assembly CS10000 320BE BOS El 100 _ Mechanical Seal Assembly CS10002 320EBS BBS El B AA PO 120 VUnloader Indicator Assembly CS12000 200F ENANA 137 Dial Unloader Indicator CS13700 200VD 200VL 150 O Ring PA 12 220 JISB2401G220 1 31 Chapter 1 Principle of Operation and Construction Screw Zi
59. VD__ X 1212121212 2 4501 o O Ring PA11025 mSB2401P25 2 2 2 2 2 2 fPO Ring VE THSBMO P33 11111414141 452 Hexagon Socket Head NB35404 010 M4 x 10 Cap Screw 453 HexagonNut 7 NCI4024 456 Hexagon Socket Head SES 010 n x Ma Cap Screw 4581 6 4 0 RI8 0 41414141414 Pug oeo RIP ppp 522 Domed CapNut 921 24 Ji lili a 523 o O Ring PA11 025 HSB2401P25 1 1 1 1 1 1 533 Spring VVasher UC ND330 00 1 1 1 1 1 1 1605 pug S 5 INF060155 _ 111111101 607 B Pug 6 RIV 1 1 a 680 A Conical Spring Washer 1 1 tT at 1 680 B ConicalSpringWasher M2 1 1 1 1 22 2 200VSD 200VMD 200VLD 200VSG 200VMG 200VLG Rotor Casing 14C6S00100 200V X8 1200V88 0717 f Jif 1_ Main Rotor Casing CS00100 200VXM 200VM L 1 _ I Main Rotor Casing _ CS00100 200VXL__ 200VL AE HATE 114 Hexagon Socket Head NB35416 050 M16 x 50 50 50 50 50 50 i Cap Screw 3 Alignment Pin NE2016 055 1 06355 4 4 4 4 4 4 4 HangerBolt 81NB600 220 080 M4141711711 1111111 1 5 SuctionCover 1C800500 200V X 200909 1 1 1 1 1 1 6 Gasket SuctionCover_____ CSO06I EV_____2001DV ____ 1 1 1 1 1 1 8 SprimgPin________ NE3206012___ 06x2_ __ 2
60. Vievvs This section shows the sectional views of the following compressor models 1 160VSD 160VMD 160VLD 160VSG 160VMG 160VLG 200VSD 200VMD 200VLD 200VSG 200VMG 200VLG 250VSD 250VMD 250VLD 250VLLD 250VSG 250VMG 250VLG 250VLLG 2 320VSD 320VMD and 320VLD 1 34 1 160VSD 160VMD 160VLD 160VSG 160VMG 160VLG 200VSD 200VMD 200VLD 200VSG 200VMG 200VLG 250VSD 250VMD 250VLD 250VLLD 250VSG 250VMG 250VLG 250VLLG ES bii A 1 p 77 TU PAZZI 2 R S NE A y R UN NOS WA 5 N b T m b m LN SY 48 N Nus b N zy SN L a AK NAAN 1 y dr x deter ASHES r YE S N WS 461 29 229 Y a A SY Xt G TEREE MAAN Uu A N d u uu EEY A SN ti k TEE AN SUN TE N S ZAN 4 a H Pree Tre a d rir d Y du A 5 mh x LI iL h T N m L May g INIT zz We TTA E 2222 E e SY UE Y e SO 14 b TM EE a a ae 1 OA sero Picco Pie ri ey see uu oOo i S i Pi SIA NOR 1 Th F b il k MN E r ann i r ni i il F L ik h 1 i giy i F dn r l m A A E H i 5 i ia d H F r
61. ader cylinder cover 9 Suction cover and side bearings 4 Unloader piston and unloader cylinder 10 Rotors and main rotor casing 5 Balance piston cover 11 Variable Vi auxiliary slide valve and unloader slide valve 6 Balance piston 12 Bearing head and main bearings 3 2 5 Disassembling Each Section 1 Mechanical Seal Assembly Disassembling the Mechanical Seal Assembly a Of the six hexagon socket head cap screws P N 53 securing the seal cover P N 51 remove four screws leaving the two diagonally opposite screws b Loosen the remaining two screws alternately a little at a time The seal cover of the mechanical seal will be raised slightly by the force of the inside spring creating a gap under the cover The gap will not be created if the gasket is sticking to both surfaces In this case free the cover by screwing the eye bolts tools supplied with the compressor into the screw holes in the seal cover to separate it c The inside oil will flow out through the gap Receive oil with a container d Remove the seal cover by pulling it out in line with the rotor shaft axis Inside the cover there is the mating ring fitted with the O ring So draw out the cover being careful not to let the mating ring be damaged by interference with the shaft e Remove the O ring P N 49 between the seal cover and oil seal retainer Fig 3 7 Removing the Seal Cover Fig 3 8 Seal Cover and Mating Ring f After the seal cover has b
62. ain block effectively whenever necessary during their handling Heavy components if dropped can cause serious consequences to both operators and equipment e Only a qualified person must use a crane There will be an increased risk of accident if an unqualified operator handles a crane In addition the operator may violate local regulations Disassembling the Bearing Cover Fig 3 38 Removing the Vi Adjusting Rod Lock Nut Fig 3 39 Removing the Bearing Cover Screws a Remove the lock nuts of the Vi adjusting rod see Fig 3 38 b Of the hexagon socket head cap screws fastening the bearing cover P N 18 1 18 2 18 3 replace the two screws at the top of the cover with stud bolts headless safety bolts and then remove all the other screws Jacking bolt holes are provided at the 2 o clock and 8 o clock positions on the bearing cover these holes are plugged with vinyl caps at the time of shipment from the factory First place a container for catching oil under the bearing cover and then install the two of the removed hexagon socket head cap screws into the jacking bolt holes and screw in them alternately to create and widen the clearance between the bearing head and bearing cover Oil will flow out as the clearance is widened d The cover will come off the alignment pins located near the screws being turned in as the clearance increases On the 200 250 and 320 models there are threaded holes at the top of the bearing cover s flange
63. ain rotor casing remove the lower 6 to 8 screws each NOTE These screvvs are removed in this stage of the procedure because they cannot be accessed after placing the entire compressor on the vvorkbench e Move the entire compressor still being lifted onto the vvorkbench Place the compressor on the vvorkbench in either of the following methods according to the compressor type e n the case of a D version model which has a discharge port facing down and thus a discharge port flange extending downward from the leg plane of the suction cover and bearing head place the compressor with the flange portion outside of the workbench edge see Fig 3 5 Alternatively place wooden brocks high enough to provide the flange with clearance from the workbench surface below the legs of the suction cover and bearing head and lower the compressor on the wooden blocks see Fig 3 6 e In the case of a G version model with a discharge port facing sideways the entire compressor can be placed on the workbench without doing any special arrangement as the flange is on the same plane as the legs of the suction cover and bearing head Fig 3 5 Extending Flange to Outside of Fig 3 6 Using Wooden Brocks Workbench 3 5 Chapter 3 Maintenance 3 2 4 Compressor Disassembly Sequence Disassemble the compressor in the following sequence 1 Mechanical seal assembly 7 Bearing cover and Vi adjusting rod 2 Unloader indicator assembly 8 Thrust bearing 3 Unlo
64. alkylene Glycols PAG PAG is much more hygroscopic compared with mineral oils PAG easily absorbs the moisture in air if handled carelessly and may constitute a cause of rusting and corrosion wear inside the system components Especially when handling Freol PN46 take care of the following Avoid replenishing oil on a rainy day or when the workplace is humid to prevent absorption of moisture Thoroughly evacuate the system and leave it overnight in order to eliminate moisture as much as possible Do not unseal the container until you start replenishing Complete the oil charging operation in a shortest possible time after unsealing the container Finish charging of oil in one container within 15 minutes Close the gap between the container outlet and the charging hose with an appropriate material to prevent entry of foreign materials and moisture A more effective method is to replace the air in the container with nitrogen gas Do not leave oil in the container and do not use remaining oil in the container afterwards PAG may damage coating so wipe off the oil on a painted surface as soon as possible 2 Handling of Polyol Ester POE POE is highly hygroscopic like PAG In addition POE is hydrolytic at high temperatures and thus entry of moisture must be strictly prevented You must observe the same precautions as those for PAG when handling POE Complete oil charging in a shortest possible time after unsealing the container for mini
65. b against the main rotor casing Also check the clearance in their fitting areas and the fitting condition between the Vi adjusting rod and unloader slide valve bushing Replace the bushing if it is worn d Inspect the rotor bore surfaces of the main rotor casing These surfaces should normally have no change in condition as the bore surface must be free from interference with the rotors If there are any contact marks with rotors on the bore surfaces there may be problems related to the rotors end shaft sections and bearings If the rotors have worn down about 0 3 or more in the outside diameter the compressor s performance will start declining e If the mechanical seal section of the rotor shaft needs to be repaired please contact the nearest Mayekawa office or sales service center 10 Bearing Head and Main Bearings Disassembling the Bearing Head and Main Bearings Separating the bearing head and main rotor casing is normally not required To remove each main bearing remove the stop ring P N 29 from the bearing cover side using pliers see Fig 3 62 and push out the main bearing If the bearing cannot be removed by pushing it tap on the bearing using a hammer through a cushioning material such as copper aluminum or plastic plate Do not strike the bearing directly with a hammer Inspecting the Bearing Head and Main Bearings Check the bore of the bearing for surface condition dimensions and foreign matter embedded in it Replac
66. becomes the maximum and the loss of power is minimized if the Vi is optimally adjusted The performance curves in Fig 1 14 show the relationship between the refrigeration capacity and the brake horse power The curves indicated by thick solid lines in the graph represent the brake horse powers most efficient for achieving the specific refrigerating capacities In a compressor with a fixed Vi value each brake horse power curve leaves away from the ideal curve in some refrigerating capacity areas On the other hand it is possible for a variable Vi compressor to set the brake horse power in the vicinity of the ideal value 1 9 Chapter 1 Principle of Operation and Construction Refrigerating capacity x1000Kcal hr Rotating speed 2 950 rpm 2000 1500 1000 200 300 Ideal change of brake horse power 250 at TC 45 C 200 Ideal change of brake horse power at 150 100 10 0 10 Evaporation temperature C Brake horse power kVV TC Condensation temperature TE Evaporation temperature SH Superheating 1 14 Refrigerating Capacity vs Brake Horse Power 1 4 Description of Components Read the following description referring to the compressor components drawings and the parts lists in section 1 6 The numbers in parentheses are part numbers 1 4 1 Rotors The male rotor P N 25 and female rotor P N 26 are supported at their both ends by the side bearings P N 28 in the suction cover P
67. conditions are different e g air conditioning cold storage and freezing The compressor however can be operated most efficiently when the Vi is matched with the load condition For example if a conventional M port compressor with the fixed Vi is used for a low compression ratio application an application with small difference between suction and discharge pressures or small 59 a pressure higher than the necessary pressure will be reached before the discharge port opens as shown in the lower right graph of Fig 1 11 This means that power will be used wastefully for unneeded compression Conversely if the same compressor is used for a high compression ratio application an application with large difference between suction and discharge pressures or large Edy the discharge port will open before the refrigerant gas pressure has risen to the necessary level This would cause the refrigerant gas in the outlet piping to flow back through the discharge port as shown in the lower left graph of Fig 1 11 unless the flowing back gas is overcome by driving the compressor using extra power 1 6 A Properly adapted Vi to load condition L Suction Compression Discharge Suction i__ Compression _ Discharge 3 Suction port closed Suction port closed 1 t 1 i 5 Discharge 2 port open 2 gt 2 3 5 E 3 Discharge port ope o i E O Pd o o gt 5
68. ction 2 5 or to use any of the listed oils in a oil refrigerant gas combination different from those shovvn in section 2 5 please consult Mayekawa offices or sales service centers for appropriateness before using the oil 2 10 2 5 3 VVhen Changing to Different Brand s Oil VVhen you intend to change lubrication oil from the current brand to another you should consider the points listed belovv CAUTION If you change the lubrication oil to an oil of another brand the new oil can be incompatible vvith the operating conditions or produce negative effects on the compressor operation As changing the oil brand requires an appropriate procedure be sure to consult Mayekavva before changing the oil brand Some lubrication oils contain additives for the purpose of improving lubricating property and preventing degradation As the additive and its amount differ from type to type and brand to brand of oil you should as a rule avoid mixing oils of different brands Mixing oils of different brands can generate undesirable substances due to reaction between additives although such a case occurs rather rarely e If change of oil brand is unavoidable recover oil not only from the compressor but also from the oil separator oil cooler condenser evaporator and ali other refrigeration system components as thoroughly as possible before supplying the new oil Flushing of the system is required in some cases Change the lubrication oil to a dif
69. cylinder cover c Install the spring and the indicator cam spring retainer into position Then insert the shaft of the indicator cam assembled in Step a above into the V ring Retain the bearing in the unloader cylinder cover by installing the bearing gland with its hexagon socket head cap screws d After making sure the indicator cam rotates smoothly attach the O ring P N 75 to the unloader cylinder cover e With the unloader slide valve in the no load position push in the cover while fitting the pin on the push rod in the helical groove on the indicator cam Secure the unloader cylinder cover with the hexagon socket head cap screws with the hole for connecting the hydraulic piping facing upward See Fig 3 116 Name Unloader cylinder cover 75 O rng 76 Hexagon socket head cap screw 8 77 Indicator cam 6660600001 _78 Ballbearing 80 Bearing gand Spring Indicator cam spring retainer Fig 3 114 Exploded View of Unloader Cylinder Cover 3 43 Chapter 3 Maintenance Fig 3 115 Seal Section Components of Fig 3 116 Installation of Unloader Cylinder Cover Indicator Cam 9 Mechanical Seal Assembly a Thoroughly clean the mechanical seal fitting portion of the male rotor and check the surface for condition Inspect the stepped portion of the shaft carefully for scratches in longitudinal direction Longitudinal scratches are harmful because they will cause refrigerant leakage see Fi
70. der slide valve and confirm that the unloader slide valve moves smoothly Next install the variable Vi auxiliary slide valve and confirm that it also moves smoothly d Na i l 4 r a em ae R ahi ra na d r 7 T ay e Fig 3 68 Plug of Oil Injection Circuit Hole 1 Fig 3 69 Plug of Oil Injection Circuit Hole 2 3 29 Chapter 3 Maintenance Fig 3 70 Installing the Unloader Slide Valve Fig 3 71 Installing the Variable Vi Auxiliary Slide Valve c Assemble the main rotor casing and bearing head These parts are not disassembled during ordinary maintenance service Tighten the hexagon socket head cap screws in a diagonal sequence a little at a time and finally tighten them to the specified torque using a torque wrench see Tightening Torques for Hexagon Socket Head Cap Screws in Chapter 4 The lower screws however should be installed simply to the state ready for final tightening when the compressor is lifted later Fig 3 72 Assembling the Bearing Head and Fig 3 73 Checking Again the Unloader Slide Main Rotor Casing Valve for Smooth Movement After assembling the main rotor casing and bearing head check again that the unloader slide valve can be moved smoothly along the surface of the port section in the bearing head d Install the Vi adjusting rod from the bearing head side and screw it into the threaded hole in the variable Vi auxiliary slide valve Do not to fa
71. e mm Model For Single Stage High Stage For Booster Lovv Stage 160V 2 200V 0 05 0 07 0 26 0 3010 28 0 3 0 31 0 35 250V 0 08 0 11 0 40 0 4410 45 0 49 0 50 0 5410 55 0 59 320V 10 17 0 2110 20 0 2410 23 0 2710 26 0 30 0 70 0 7610 73 0 7910 77 0 8310 81 0 87 End Clearance Adiustment li There is a clearance equivalent to the end clearance so the bearing outer races are free to move Set the dial indicator to zero Reduce the end clearance to zero when the end clearance is zero Turn the lock nut to move the rotor to the discharge side Fig 3 97 End Clearance Adjustment by Pushing the Rotor toward Discharge End End Clearance Adjustment Il By tightening the thrust bearing gland the bearing outer races are fixed with no end The dial indicator reading after tightening the thrust clearance left The rotor moves toward bearing gland indicates the end clearance the suction side creating an end clearance Fig 3 98 End Clearance Adjustment by Tightening the Bolts for Thrust Bearing Gland c Procedure for end clearance adjustment Perform the following adjustment procedure for both the male and female rotors After the adjustment measure the end clearance and perform the adjustment again if necessary 1 When end clearance is larger than the specified value The distance between the rotor end surface and the discharge
72. e the main bearing if the inspection result shows any defect Always replace the O rings P N 450 and 523 of the Vi adjusting rod x gt 1 de Fig 3 62 Removing the Stop Ring Fig 3 63 O Rings of Vi Adjusting Rod 3 27 Chapter 3 Maintenance 3 3 Reassembly Be sure to use only MAYEKAWA genuine parts for replacement Use of substitute parts may result in serious problems in the compressor or other equipment in your refrigerating system during operation After completing inspection necessary repairs and determination of the parts to be replaced proceed to reassembly of the compressor Almost all reassembly procedures are reverse to the disassembly procedures Before starting reassembly operation clean all parts tools and workbench surface Also have fresh compressor oil ready to use for coating the components with it as necessary 1 Bearing Head and Main Bearings a The main bearings may be clearance fitted in some compressors while they may be fitted with slight interference in other compressors This is due to allowable difference within tolerances In the case of installing a bearing that is to be interference fitted make a simple jig consisting of a disk that is slightly smaller in diameter than the rim of the bearing and has a hole threaded or not in the center a long bolt with threads on its entire length a nut for the bolt and a rectangular plate with a loose hole as shown in Fig 3 65
73. een removed wipe clean the shaft and then check its surface If any scratches are found smooth out the surface with fine emery paper in order to prevent damage to the O ring when the mechanical seal is pulled out g Loosen the set screws P N 111 securing the seal collar P N 109 about three turns To do this use different methods according to the compressor model In the case of a 160 model compressor first remove the plugs from the bearing cover and then insert a wrench in each hole to loosen the inside screw In the case of a 200 or larger number model compressor loosen the set screws from the seal cover fitting section Do not remove the set screws completely but loosen them by the amount necessary to make their ends 3 6 retract from the surface of the seal collar These screws are located in two places 90 degrees apart from each other 4 ni i n Ai m k n 1a Ta Fig 3 9 Loosening the Set Screws on Seal Collar Fig 3 10 Seal Retainer h Pull out the mechanical seal assembly by holding the seal collar section with your fingertips While removing the assembly make sure that the ends of the set screws do not touch the shaft surface Any scratches on the shaft will cause leakage i Remove the two set screws from the oil seal sleeve j Screw two eye bolts into the jacking screw holes in the seal retainer and pull out the seal retainer while keeping it in parallel with the shaft
74. end of the bearing head is too large when the thrust bearing is fastened by the thrust bearing gland The distance must be reduced by either of the following methods in this case e Method 1 Dimension A in Fig 3 97 is too large because the thrust bearing alignment spacer is too thick The spacer must be ground down by the amount equivalent to the difference between the measured and specified values Use a high precision surface grinding machine for grinding the spacer After 3 38 grinding check the spacer for even thickness using a micrometer on its entire perimeter This method can be applied to all compressor models e Method 2 Insert a shim of an exactly necessary thickness between the thrust bearing gland and the outer race of the thrust bearing The thickness of the shim should be equal to the difference between the measured and the specified values like with Method 1 Shims are available from MAYEKAWA 2 When end clearance is smaller than the specified value The rotor becomes unable to rotate when the lock nuts are tightened to a certain extent This condition is caused by too small thickness of the thrust bearing alignment spacer or excessive thickness of the thrust bearing outer race spacer Use either of the following methods according to the compressor model to adjust the end clearance properly e Method for the 160 and 200 models that have thrust bearing outer race spacer Grind the spacer down to the necessary thickness usin
75. ents of Thrust Bearing Section 160 and 200 Models Fig 3 50 Components of Thrust Bearing Section 250 and 320 Models The 250 models do not have the following components oil supply ring at the center of P N 38 and O ring Fig 3 51 Sectional Views P N 150 Inspecting the Thrust Bearings a Clean each thrust bearing thoroughly then remove cleaning solvent with compressed air First check that the surfaces of all balls are uniformly bright and free of any abnormalities such as damage and flaking Next check that the thrust bearing s ball cage is free of bent or worn edges at the holes inside which balls are retained Replace the bearing set in the case of any defect 3 23 Chapter 3 Maintenance b Hold one of the bearings vvith the inner race facing dovvn and spin the outer race by hand Make sure the side facing invvard vvhen assembled is at the bottom If the outer race does not rotate smoothly or is irregular or sticky to rotate foreign materials or damaged surfaces may be causes n the event of such conditions re inspect the bearing set and vvash or replace it as necessary 8 Suction Cover and Side Bearings Disassembling the Suction Cover and Side Bearings a Remove all hexagon socket head cap screws fastening the suction cover to the main rotor casing Several screws at the lower positions were already removed during the movement of the compressor to the workbench described in 3 of Section 3 2 3
76. f the unloader indicator cam Also secure the micro switch while mating the micro switch roller with the concaved part of the micro switch cam see the sections indicated by the arrows in Fig 3 128 b Assemble the potentiometer while fitting the spring pin on its shaft into the keyway notch in the micro switch cam and fixing with the dial plate support 2 P N 135 see Figs 3 129 and 3 130 3 49 Chapter 3 Maintenance Fig 3 130 Positioning Mark on Potentiometer Fig 3 131 Micro svvitch c Install the dial plate and secure the pointer while aligning it with the no load position Adjust the full load side micro switch by moving the unloader piston to the full load position using air pressure so that the micro switch can correctly send a signal at the full load position d After performing the above test reconnect the control wiring and install the unloader indicator cover Be careful not to pinch wires under the cover 3 50 Chapter 4 Service Data This chapter contains various data necessary for servicing the SCV Series Screvv Compressors including the standards and material specifications of replacement parts and lists of the tools used for servicing the compressors End Clearance mm e Single High Stage Booster Low Stage 160V 0 04 0 06 0 20 0 22 10 22 0 24 0 24 0 26 200V 0 05 0 07 0 26 0 30 10 28 0 32 0 31 0 35 250V 0 08 0 11 0 40 0 44 10 45 0 49 10 50 0 54 0 5
77. ferent brand only after checking the supplier of the oils to make sure such change does not cause any problem If the new and old oils are produced by different manufacturers ask both the manufacturers for possible problems that result from the change of oil e If you consider changing oil to a one of different viscosity grade but of the same brand confirm that the change will not cause any problem in compressor operation The equipment type and flow design e g type of evaporator and whether oil return lines are provided or not of the refrigerating system should vary with the characteristics of the lubrication oil used inter soluble oil or non inter soluble oil For this reason any change from inter soluble oil to non inter soluble oil should be prohibited In the case of change from a non inter soluble oil to an inter soluble oil it is essential to select oil of an appropriately high viscosity that assures proper viscosity levels even when the refrigerant resolves into the lubrication oil supplied to the compressor which will lower the viscosity level Chapter 2 Essential Points for Operation 2 5 4 Points to Be Noted for Handling of Lubrication Oil For replenishment use only clean lubrication oil from a well sealed container Oil kept in open container may have absorbed moisture and be contaminated with dust and other foreign materials When adding lubrication oil prevent air and moisture from entering the oil 1 Handling of Poly
78. g csozo 6000 r ririririr Stop SM yy 80 Bearing Gland UC h CS08000 200 200 0 MAA CA E IE 2111 81 Hexagon Socket Head Cap NB35406 015 A x 15 Screw 82 1 Vring 508200 200 20x10x1 1 1 1 83 1 C808300 200 200 1 1 1 84 Retainer Indicator Cam Spring CS08400 200 200 1 1 1 1 91 Shaftkey 509100 1600 t60 1 1 1 1 1 1 92 Suction Flange h CS71400 P125 1 1 1 1 1 1 93 Gasket Suction Flange CR72000 125N T L L I1 1171 94 Hexagon Head Bolt y 1NB12020 055 1M20x55 1817818181818 95 Discharge Flange 1CS71400 P 00MCD 1 1 fif f 5 a L i IMM 96 dGasket G Discharge Flange CR72000 100N 1 m8 97 Hexagon Head Boli 1NB12022 055 M22x55 97 Hexagon Head Bolt NB12022 080 M22 x 80 in Japan 100 Mechanical Seal Assembly CS10000 160BT BOSTI 1 1 1 1 1 1 1 21 Chapter 1 Principle of Operation and Construction 100 Mechanical Seal Assembly CS10002 160EBS__ BBS E1 1 1 1 1 1 1 120 Unloader Indicator Assembly CS12000 200F 1782 L L LI 117111 Be r A O A O 235 o Spacer Discharge Flange FX101 10 J 82 F LT T L1 f kim I Spacer 237 Torsional Slip VVasher 1 CS23700 160 l60 2 2 2 2 2 2 250
79. g 3 117 Press fit the oil seal into seal retainer With the compressors produced in and after 2003 the sealing b edge is on the opposite side to that in the compressors produced in the preceding period see Fig 3 118 NOTE Oil seal having sealing edge on any side is acceptable except for the mechanical seal having an oil pot c Screw the eye bolts into seal retainer Push in the seal retainer with the oil release hole at the top and the rotation preventing notch aligned with the pin inside the seal cover Turn the seal retainer in both directions to make sure the pin is fitted in the notch Fig 3 118 Notch in Seal Retainer Fig 3 117 Oil Seal and Seal Retainer d Attach the O ring into the oil seal retainer do not fail to do this see Fig 3 119 For the 200 and 320 models fit the oil seal sleeve in position and secure it by screwing the two set screws while aligning them with the countersinks in the shaft see Fig 3 120 3 44 Fig 3 119 O Ring for Seal Cover Assembly 200 and 320 Models e Install the mechanical seal assembly on the shaft Then push the seal ring by hand to check it for axial movement Push in the O ring P N 112 being careful not to cause damaged to it by the step on the shaft f Install the shaft seal collar by tightening the two hexagon socket head set screws while aligning them with the countersinks in the shaft Failure to align the screws with the countersinks will
80. g the refrigerant gas The male rotor is directly coupled to a two phase electric motor and driven at a standard speed of 2 950 rom with a 50 Hz power supply or 3 600 rpm with a 60 Hz power supply If necessary the speed may be changed using an inverter or a gear set One end of each rotor constitutes the gas suction end while the other end the compressed gas discharge end While the rotors are rotating over a certain angular range their suction ends open the suction port the suction ends close the port while the rotors are rotating over another angular range This is also true with the discharge ends and the discharge port see Fig 1 3 Suction flange Discharge flange d Fig 1 2 Rotors in Main Rotor Casing Fig 1 3 Suction and Discharge Ports in Rotor Casing 1 2 1 2 1 Suction Phase VVhile both rotors suction ends are rotating over the suction port opening range the cavity formed by the screvv lobe grooves and the casing gradually expands vvhich causes refrigerant gas to be sucked into the cavity VVhen the volume of the cavity becomes the maximum the rotors suction ends start rotating over the suction port closing range Since the rotors discharge ends start rotating over the discharge port closing range at the same time the cavity becomes a completely closed space see Figs 1 4 to 1 7 Fig 1 6 Gas Suction Phase s About to End Fig 1 7 Suction Port Closed 1 3 Chapter 1 Principle of O
81. g the same method as the Method 1 in 1 above e Method for the 250 and 320 models that have no thrust bearing outer race spacer Inserted a shim of a necessary thickness between the thrust bearing alignment spacer and the thrust bearing NOTE We recommend ordering a new thrust bearing alignment spacer of the desired thickness from MAYEKAWA rather than using a shim d Rotate the male rotor by hand to check for smooth rotation e Check runout of the shaft by applying the dial indicator s probe to the mechanical seal portion of the male rotor and rotating the rotor see Fig 3 100 A runout of up to 0 03 mm is acceptable for all models Runout is generally caused by non uniform thickness of the thrust bearing alignment spacer non alignment of the mark across the bearing halves or existence of foreign materials between the bearing s inner or outer race and the spacer Even with a proper end clearance runout of the rotor shaft significantly affects its seal performance If runout is excessive disassembly and adjustments are necessary for the thrust bearing outer race spacers thrust bearing alignment spacers and all areas related to the main bearings f After completing the end clearance adjustment and subsequent tightening bend the claw of the lock washer Then bend the washers of the hexagon head bolts for the thrust bearing glands to lock the bolts Fig 3 99 Installing Conical Spring Washer under Head of Thrust Bearing Gland Bolt
82. h base plate P N 121 to the unloader cover d Remove the micro switch base plate by pulling it out in parallel with the axis of the indicator cam Chapter 3 Maintenance Fig 3 17 Removing the Micro svvitch Base Fig 3 18 Removing the Micro svvitch Base Plate Plate Screvvs Fig 3 19 Exploded Vievv of Unloader ndicator 3 Unloader Cylinder Cover The unloader cylinder cover P N 74 is at the end of the unloader cylinder Behind the unloader cylinder cover there are the indicator cam seal and ball bearing Unless an abnormal operation due to a leaky seal or worn indicator cam groove is noticed disassembly of the unloader cylinder cover and indicator cam assembly is not needed Removing the Unloader Cylinder Cover a Remove the hexagon socket head cap screws P N 76 that fasten the unloader cylinder cover to the unloader cylinder b The indicator cam P N 77 installed in the unloader cylinder cover is fitted in the bore of the unloader push rod P N 67 inside the cylinder and the guide pin P N 68 implanted in the push rod is engaged with the groove cut in the indicator cam Pull out the unloader cylinder cover in parallel with the axis of the push rod Fig 3 22 Unloader Push Rod and Indicator Cam Fig 3 23 Unloader Cylinder Cover 3 13 Chapter 3 Maintenance Fig 3 24 Exploded Vievv of Unloader Cylinder Cover Fig 3 25 Indicator Cam Seal Section Components Inspecting the Unloader Cylinder Cover a
83. h side bearing P N 28 by first removing the stop ring P N 29 see Fig 3 54 and then applying pressure on its rotor side to force the bearing out The side bearing is either interference fitted or clearance fitted due to manufacturing tolerances If the bearing is interference fitted hummer it not directly but through a cushioning material such as a copper aluminum or plastic plate Replace the O ring P N 433 around each bearing 3 24 Fig 3 54 Removing the Side Bearing Stop Ring Fig 3 55 O Ring Gland of Unloader Push Rod Inspecting the Suction Cover and Side Bearings a Inspect the unloader push rod P N 67 Replace the push rod if it is deformed or has damage on the outer friction surface Always replace the O ring P N 73 of the unloader piston fitting section b Inspect each side bearing for foreign objects embedded in the inner friction surface Also measure the dimensions of the bearing Replace the bearing if necessary according to the inspection result 9 Rotors Main Rotor Casing Variable Vi Auxiliary Slide Valve and Unloader Slide Valve The variable Vi auxiliary slide valve and the unloader slide valve are assembled together inside the main rotor casing while being guided by each other Disassemble them after removing the rotors Disassembling the Rotors Main Rotor Casing Variable Vi Auxiliary Slide Valve and Unloader Slide Valve e As each rotor is heavy in weight handle it very carefully u
84. il to install the thrust washer see Fig 3 41 e Check that the gasket does not protrude into the rotor rotating bores on the bearing head end of the main rotor casing If any part of the gasket is extending into the bores cut away that part with a knife or the like Otherwise the exposed part of gasket is caught between the end surface of the rotor and bearing head preventing proper thrust clearance adjustment and eventually causing degraded performance of the compressor 3 30 3 Main Rotor Casing and Rotors a Apply oil to the shaft portion on the bearing head side of the female rotor and also the inside of the female rotor s main bearing Install the female rotor into the main rotor casing To do this suspend the rotor s midpoint using a rope or strap from a crane or chain block and insert the rotor into the casing halfvvay along its length vvhile keeping it balanced on the rope or strap Then detach the rope or strap from the rotor and push the rotor fully into the casing You may also install the male rotor first as long as the lobe mating vvork in Steps b and c below is correctly performed WI a 4 Fig 3 74 Stamp Mark on Suction Side Lobe End Fig 3 75 Stamp Marks on Discharge Side Lobe of Male Rotor End of Female Rotor Each rotor has a lobe end mark s stamped number mark s on both the discharge side and suction side ends in such a vvay that the mating marks can be confirmed even vvhen the male rotor is in
85. l Suction volume control of each compressor The unloader cylinder is connected to the unloader indicator assembly P N 120 via the indicator cam P N 77 allowing the indicator to indicate the positions of both the variable Vi auxiliary slide valve P N 289 and the unloader slide valve The indicator cam has a spiral groove in which the guide pin P N 68 implanted in the unloader slide valve push rod P N 67 is movably inserted As this pin and cam combination converts a linear displacement of the unloader slide valve into an angular displacement the pointer of the indicator indicates the position of the valve In addition to the visual reading of the position of the unloader slide valve the unloader indicator assembly can also provide the following electric signals for output to external devices ON OFF signals produced by the cam mechanism contacts and resistance signals produced by a potentiometer The contact resistance type potentiometer is provided as standard equipment and an explosion proof type potentiometer is also available as optional equipment Chapter 1 Principle of Operation and Construction 1 4 4 Oil Supply System Lubrication Oil and Capacity Control Hydraulic Oil Depending on applications the SCV Series Screw Compressors use either of the following types of oil supply system e Forced oil supply system This system uses pump pressurized oil for both the lubrication and capacity control purposes Type A Diffe
86. lling the Bearing Cover 7 gt 325 4 Fig 3 104 Safety Bolts for Retaining the Bearing Cover 7 Balance Piston Cover Unloader Cylinder and Unloader Piston a Attach the O ring P N 65 on the unloader piston and put the cap seal P N 66 over it Insert the piston into the unloader cylinder from the roundly chamfered end rotor casing side see Fig 3 106 Turn the piston s side vvith the eye bolt holes tovvard the unloader cover so that the cap seal can be fitted between the unloader cylinder and O ring b Attach the O ring P N 63 to the unloader cylinder s portion where the cylinder comes in contact with the suction cover see Fig 3 107 and install unloader cylinder to the balance piston cover see Figs 3 108 and 3 109 Install the unloader cylinder to the suction cover using the hexagon socket head cap screws P N 61 at two places a Fig 3 107 Installing the O Ring Fig 3 106 Unloader Cylinder and Unloader Piston 3 41 Chapter 3 Maintenance b 4 ea a ili AT i L Fig 3 108 Installing the Unloader Cylinder Fig 3 109 Installing the Unloader cylinder on to Balance Piston Cover Balance Piston Cover c Move the unloader push rod fully toward you full load position then fit the balance piston cover gasket P N 23 to the balance piston cover see Fig 3 110 and push the unloader cylinder into the suction cover The unloader
87. main with the product when you resell it to another user All the descriptions instructions and data contained in this manual are based on the information that are available at the time of producing the manual Mayekawa reserves the right to make changes to the product for improvements without prior notice If you have any query due to inconsistency between the product and the information in this manual that can result from such changes please ask questions to any of the office or sales service centers listed at the end of this manual Important Safety Information Be sure to thoroughly read this manual before operating or servicing the product in order to familiarize yourself with the instructions and recommendations in it During operation and servicing of the product we urge you to follow these instructions and recommendations Failure to follow these instructions and recommendations will or could result in death or personal injury and also may cause operational problems or damage not only to the product but also to the related equipment in your system Throughout this manual the instructions especially important for assuring safety and preventing property damages are highlighted using the symbols letters shown below You should understand what each symbol letter alerts to before using this manual Indicates a hazardous situation which if not avoided will result in death or serious 4h DANGER injury Indicates a hazardous situation which if
88. mum contact with air Try to completely use the oil in the container If it is unavoidable to leave part of the oil in the container cap and seal the container s outlet completely and keep it indoors Limit the storage time only to a short period As POE is hydrolytic periodic oil analysis is recommended to check degradation in quality 2 5 5 Quality Management of Lubrication Oil 1 Quality management criteria Lubrication oils are classified into the following three categories and different quality criteria are applied to each category synthetic oils Polyalkylene glycols PAG Mineral oils Naphthenic base oils and paraffinic base oils synthetic oils Alkylbenzene AB and Polyalphaolefine PAO synthetic oils Polyolesters POE We recommend performing sampling oil analysis every six months If any of the criteria except for the water content of PAG is not met oil replacement is required 2 12 The analysis items and the criteria for each of the oil categories are indicated in the following tables Please note that these criteria may be changed without notice Synthetic oils PAG a Color Max L4 0 according to ASTM D1500 b Total acid number TAN Max 0 1 mg KOH g c Kinematic viscosity Within 10 in variation when compared with fresh oil d Water content Max 2 000 ppm See Note1 Max 2 000 ppm See Notet e Contamination level Max 15 mg 100 ml as measured by gravimetric Millipore filter meth
89. n Flange _____ CS7I400 P250 MYK250A_ 1 1 1 93 _ Gasket Suction Flange 509300 2500 MYK250 1 1 Il 1 94 HexagonHeadBolt 1NB12024 065 M24x65_ 12 12 12 12 95 Discharge Flange 571400 151 0 MYKISOCD 1 1 1 1 ESE 95 TDischarge Flange CS71400 P150 MYKISOA 96 Gasket G Discharge Flange CR72000 150N___ MYKI50A 97 Hexagon Head Boli NB12022 055 22255 181818178 100 Mechanical Seal Assembly 510002 25 2 lset Iset Iset Iset 100 o Mechanical Seal Assembly CS10002 250EBS BBS El lset Iset 1201 Unloader Indicator Assembly CS12000 200F 1200V laet Iset Iset Tset 1set 137 Dial Unloader Indicator cs13700 00VD 200v 215 Flange Lubrication Oil Supply CR74000 025 2 L TL L L L L a UT PA pp Supply Flange l l l 2 l bi b ik et et et 1 1 1 217 Hexagon Head Bolt 15512 035 12 235 141414 4 1414 1 1 2 2 1 1 4 1 1 4 5 1 EA AE A K CARE ESA ls set 1set 1 ne E m 2 235 o Spacer Discharge Flange 1FX101 250 1250 _ 1 1 1 7 x 2 NE 236 Gasket Discharge Flange CS23600 250N 5077 1 Spacer 2 2 237 Torsional Slip Washer 523700 250 2 1 Electromizer Flange CS71400 050 MYK50A 2 2 ms MESA 4 ae LA NEN 1
90. nCover______ CSO061 DV_____ I60LDV ____ 1 1 1 1 1 1 8 SpringPin gt lt 1NE3204 000 4x10____ 2 2 2 2 2 12 9 7 0 Ring PAII0466 JISB2401P46 1 1 1 1 1 1 O DA Pug L it 1 1 1 1 t_ 10 B Plg UC NF06 008 R14 10 C Pug 6 8 1 10 D Pg UC NF0600 3 8 11 BearingHead H CS01100 160VXD 160V 1 11 BearingHead UC 501100 160 160 55 12 Gasket BearingHead CSOI200 160N 160 1 13 HangerBolt h NB600 127 MI2 011 14 SpringPin 97NH3204 010 104x10 2 16 BearingCover CS01600 160VXD 160V 1 16 BearingCover CS01600 160VXG 1 160V 66 17 Gasket D Bearing Cover CS01700 160VD 1160V 1 17 Gasket G Bearing Cover 1C801700 160VG 1160V 6 du x suz Cap Screvv be ikm mera TTI Cap Screw 19 AlignmentPin NE2010 000 1 00244 2 2 2 2 2 2 20 Spring Pn NE32030010 3x10 1 1 1 1 1 1 exe fon Cover __ _ 23 Balance Piston Cover CS02300 160N 11607 24 Hn Socket Head NB35410 025 a x 25 Cap Screw 25 Male Rotor CS02500160VS 1160V88 1 1 26 Female Rotor T 25 MaleRotor 502500 1600 160VMF J if 1 1 1 26 Female Rotor VM Jr 25 MaleRotor CS02500 160VE ILE 1 11 J 26 Female Rotor mt i i
91. nes b Replace the O rings every time the mechanical seal assembly is inspected because they normally swell and deform over time A total of four O rings are used for the sealing section They are located between the seal cover and seal retainer P N 49 between the mating ring and seal cover P N 103 between the seal collar and shaft P N 112 and between the seal cover and oil seal sleeve P N 744 c Inspect the oil seal sleeve for wear in its section rubbing against the oil seal lip If wear is evident replace both the oil seal P N 50 and oil seal sleeve P N 528 with new parts Since the oil seal is made of a special material only a genuine oil seal must be used for replacement d Replace the seal cover gasket with a new one 3 10 Fig 3 14 Seal Retainer and Oil Seal Sleeve 2 Unloader Indicator Assembly Removing the Unloader Indicator Assembly a Remove the three bolts P N 147 fastening the indicator cover P N 146 As the glass P N 141 and glass spacer P N 142 are easy to detach be careful not to drop them Fig 3 15 Removing the Indicator Cover Fig 3 16 Loosening the Micro switch Cam Screws b Behind the unloader indicator dial there is the micro switch cam that connects the potentiometer to the indicator cam Loosen the screws P N 128 on the indicator cam side unloader cover side to free the indicator cam c Remove all the hexagon socket head cap screws P N 122 that fasten the micro switc
92. ng side female rotor side see Fig 3 33 To undo the lock of the sleeve either remove the male rotor side screw or loosen the female rotor side screw and screw in the male rotor side screw e With the balance piston sleeve locked by the Type 2 method simply remove the stop ring of the sleeve to undo its locking see Fig 3 37 f Pull out the balance piston sleeve The sleeve is loose fitted so it can be removed easily g Remove the O ring P N 35 and spacer behind the sleeve h Ifthe side bearings are to be removed remove the stop rings located further inside as well Inspecting the Balance Piston and Balance Piston Sleeve Check the balance piston sleeve for wear replace the sleeve if it is worn Be sure to replace all the O rings with new ones By their elasticity the O rings work to center the clearance round the periphery of the balance piston sleeve on the center of the balance piston 6 Bearing Cover Removing the Bearing Cover The bearing cover differs in shape between the D version models with a bearing head for sideways discharging and the G version models with a bearing head for downward discharging The discharge port is in an unsymmetrical location with the D version models so the bearing cover has imbalanced weight distribution between the right and left this requires careful handling of the bearing cover during its removal e Handle heavy components extremely carefully Use a crane and ch
93. nstall the above parts in the following sequence Thrust bearing Thrust washer Lock washer Torsional slip washer Lock nut Be sure to replace the lock washers with new ones If the washers are reused the same claws on them have to be bent again and may break eventually lf the thrust bearings are replaced change in the bearings end clearance and consequential adjustment must be assumed during the assembly Tighten each lock nut a little at a time while making sure of presence of the necessary end clearance 3 35 Chapter 3 Maintenance e When new thrust bearings are installed their end clearance will change because of tolerable machining difference in end to end dimension between the inner and outer bearing races Accurately measure the end clearance using the method of Step b below and adjust the end clearance correctly If the lock nut is fastened when there is no end clearance the balls will be pressed against the rolling contact surfaces of the bearing and this will cause dimples on the surfaces b With the inner race of the thrust bearing firmly fitted on each rotor shaft measure the rotor end clearance for each of the male and female rotors and then adjust the end clearance using the following method 1 Press the rotor against the discharge end surface 2 Mount a dial indicator on the suction cover end of the main rotor casing with a magnetic stand apply the dial indicator s probe on the end surface of the rot
94. od See Note2 Mineral oils and synthetic oils AB and PAO b Total acid number TAN Within 15 in variation when compared with fresh oil Max 100 ppm See Note1 Max 100 ppm See Notet oo e Contamination level Max 15 mg 100 ml as measured by gravimetric Millipore filter method See Note2 Synthetic oils POE a Color Max L4 0 according to ASTM D1500 b Total acid numner TAN Max 0 2 mg KOH g c Kinematic viscosity Within 10 in variation when compared with fresh oil d Water content Max 200 ppm See Note1 Max 200 ppm See Notet O e Contamination level Max 15 mg 100 ml as measured by gravimetric Millipore filter method See Note2 NOTE 1 Synthetic oils inter soluble with ammonia are so highly hygroscopic that they can absorb moisture at the time of sampling In addition the ammonia content they have absorbed may be detected as the water content at the time of the analysis making it difficult to precisely measure the water content Therefore use the criterion value only as a reference 2 contamination level criterion assumes the use of an oil filter with nominal mesh size at 15 um or finer 3 The above criteria are applicable only to refrigeration systems 2 13 Chapter 2 Essential Points for Operation 2 5 6 Lubrication Oil Replacement Intervals 1 After initial startup of the system Oil may become contaminated and deteriorated relatively quickly after startu
95. onsidering the influence on the O rings used in the compressor in addition to all other necessary factors including the compatibility with the refrigerant The following lubrication oils are recommended for the use with the MYCOM SCV Series compressors also from the problem preventing viewpoint Oils for systems using ammonia refrigerants 1 Polyalkylene Glycols PAG based synthetic oils mm s Freol PN46 JOMO PN46 is only one type of inter soluble oils that can be used with an ammonia refrigerant 2 Mineral oils non inter soluble mm s Naphthene base GARGOYLE ARCTIC 30001 68 S ExxonMobil Texaco Hydrotreated CP 1009 68 560869 CP CS paraffinic base Texaco RHT 68 A ETE 2 9 Chapter 2 Essential Points for Operation 3 Synthetic oils non intrer soluble mm s AB Mycold AB68 ZERICE S68 0688 ExxonMobil Exxon Mobil BERREL FREEZE 46S Matsumura Oil Co Ltd CP 80807 CPI GARGOYLE ARCTIC SHC 224 30 Exxon Mobil See note GARGOYLE ARCTIC SHC 226 E 577 Exxon Mobil See note Note Use only a mechanical seal of the standard BBSE type Oils for systems using HFC refrigerants 1 Polyol Ester POE synthetic oils for R404A R507A and R410A inter soluble mm s SUNISO SL 68S POE EMKARATE RL68H 2 Polyol Ester POE synthetic oils for R134a inter soluble mm s Freol a100 CAUTION e If you intend to use a lubrication oil of a brand not listed in se
96. or shaft then set the dial indicator needle to zero 3 Fasten the thrust bearing gland with four hexagon head bolts evenly then finally tighten them to the torque indicated in the table below or Tightening Torques for Hexagon Head Bolts P N 45 of Thrust Bearing Glands in Chapter 4 see Fig 3 94 4 As the thrust bearing gland bolts are fastened the rotor is pushed toward the suction cover and the amount of the displacement is indicated on the dial indicator An end clearance equal in amount to the dial indicator indication is created on the rotor s discharge end see Fig 3 95 5 The end clearance is correct if the dial indicator reading is within the relevant range shown in the table on page 3 38 If the end clearance is too small change the thrust bearing alignment spacer to a thicker one or add a shim of the necessary thickness Shims for all models are available from MAYEKAWA if the thinnest of the shims is still too thick for the adjustment thin it down by grinding to the desired thickness Refer to Step c for the method of the adjustment ig Fig 3 94 Installing the Thrust Bearing Gland 3 36 K pi g si i Fig 3 96 Tightening the Hexagon Head Bolts to the Specified Torque Tightening Torques for Hexagon Head Bolts of Thrust Bearing Glands 255 Tightening Torque 160V 400 kgf cm 200V 500 kgf cm 250V 600 kgf cm 320V 1200 kgf cm 120 N m 3 37 Chapter 3 Maintenance End Clearanc
97. p of the refrigeration system due to scales and deposits remaining in piping and vessels Therefore the first replacement of lubrication oil should be carried out at 500 hours after the initial startup of the system 2 During regular operation Lubrication oil deteriorates gradually as the system is operated over time Although the rate of deterioration of the oil varies with operating conditions the type of oil and the amounts of foreign substances and moisture content in the oil we recommend replacing the oil every 5 000 operation hours or every year whichever comes first If oil filters frequently clog or the oil has turned dark and unclear replace oil after removing the cause of problem 2 14 Chapter 3 Maintenance 3 1 General This chapter describes the procedures for disassembly inspection replacement of parts and reassembly of the SCV Series Screw Compressors The procedures for servicing the unloader indicator assembly are also included in this chapter NOTE The part numbers P N indicated in the following procedures correspond to those in Sections 1 6 1 Component Drawings and 1 6 2 Parts List e Chapter 4 of this manual provides the data and information on parts and tools necessary for servicing this product Refer to Chapter 4 as necessary 3 2 Disassembly and Inspection Disassemble the compressor in the sequence indicated in each procedure Inspect and handle components only after understanding the inst
98. pending on the type of the refrigerant used in combination with the oil If the refrigerant dissolves in the oil or the oil and refrigerant are inter soluble the viscosity of the oil drops to a level remarkably below the level required for operation of the compressor under some operating conditions On the contrary if the refrigerant does not dissolve in the oil or the oil and refrigerant are non inter soluble the viscosity may become too high when the supply oil temperature is low For this reason the lubrication oil must be selected so that its viscosity is proper 13 40 cSt when supplied during operation of the compressor In a refrigeration system using a screw compressor the lubrication oil supplied to compressor is discharged together with the compressed refrigerant gas and separated from the refrigerant by an oil separator However the oil cannot be separated completely in the oil separator so very small part of the oil enters the condenser and can remain there Part of the oil can also enter the evaporator For this reason the lubrication oil must be thermally stable under high temperatures be separable from the refrigerant gas and maintain adequate fluidity under low temperatures Note that some lubrication oils are incompatible with a certain type of refrigerant For example Polyo Eester POE synthetic oil cannot be used with ammonia refrigerant 2 8 2 5 2 Recommended Lubrication Oils The lubrication oil must be selected c
99. peration and Construction 1 2 2 Compression Phase As the rotors further rotate the sealing line formed by the screvv robe grooves and the casing vvall moves toward the discharge end gradually decreasing the volume of the cavity The refrigerant gas trapped in the cavity thus gets compressed see Fig 1 8 Fig 1 8 Compression Phase 1 2 3 Discharge Phase Just when the preset Vi value is reached as a result of reduction in volume of the refrigerant gas compared with the volume just before the start of compression rotation of the rotors discharge ends enters the discharge port opening range This allows the compressed refrigerant gas to be discharged through the discharge port see Fig 1 9 Fig 1 9 Discharge Phase 1 4 1 3 Internal Volume Ratio Vi 1 3 1 What Is the Internal Volume Ratio Vi In the case of reciprocating compressors the refrigerant compression capacity is controlled by setting the pressure attained by piston displacement to an optimum level for the intended application With screw compressors on the other hand the compression capacity is controlled by setting the extent to which the volume of the sucked refrigerant gas is to be reduced In other words the compression capacity control applied to the screw compressor is a volumetric ratio control This volumetric ratio is called the internal volume ratio and defined by the following formula Vi Volume of suction refrigerant gas just before star
100. power and thus constitute no reason for changing the Vi setting However the temperature difference between the summer and the winter is besides the change in application a typical factor that requires change of the Vi setting Typical case that requires Vi setting change When the application of the compressor is changed from a cold storage system evaporation temperature at about O C to a refrigeration system evaporation temperature at 40 C the brake horse power in the new application will be 1 5 times as large as that of the old application if the Vi remains at the L port setting It is recommended to change the Vi setting to the H port setting for the new application Typical case that does not require Vi setting change With a compressor that is used for a freezing system in which the evaporation temperature varies between 0 and 30 C as time passes the Vi setting should not be changed according to the change resulting from rises in compression ratio The compressor should be used with the Vi fixed at the original M port setting in this case The same Vi setting should be maintained during operation of the compressor In the case of a special application that requires frequent adjustment of the Vi to match it with varying operating condition it is recommended to use a Maximizer screw compressor produced by Mayekawa as another series product that incorporates a mechanism for hydraulically adjusting the position of the variable Vi
101. quare Washer 1C844600 200010 1 1 1 111171 448 Teflon Bushing 1C844800 20000 0271711 1111111 1 449 Thrust Washer 544900 200 __ 2 2 2 2 2 2 4501 O Ring_____ PAI 03S YISB2401P353 2 2 2 2 2 2 O Ring___ PAI1 035__ uisp24oip35__ 1 1 i tf 1 1 452 Hexagon Socket Head NB35405 015 M5 x 15 Cap Screw 453 HexagonNut_______ NCI4030 M30 EA 456 Hexagon Socket Head NB35405 010 MS x Cap Screw E la 48 Plug ooo NFGO 1 148 4 4 4 4 4 pe nfosoro pa pin p 522 Cap Nut NC921 30_ 0 M0 72 a 323 Foks pars smi aoa 528 Sleeve OilSeal_________ CS52800 200VD__ 200V _____ 1 1 1 1 1 529 SetScrew NA83606 005 M6x8 20053 2 2 2 2 2 533 SpringWasher____ ND33005 o 1 1 1 1 1 6051 Puig ______ NF0600 O RA pa 607 A NF06 004 RIA Jaor 1 1 1 EG07 BBs Noco Rit ij il 680 Conical Spring Master mio 5 ez EE Ez 2 EN AE i 211 680 B Conical Spring Washer 0 Ji 1 J EE 1 25 Chapter 1 Principle of Operation and Construction 3 250VSD 250VMD 250VLD 250VLLD 250VSG 250VMG 250VLG 250VLLG 1 Man Rotor Casing CS00100 250V X85 250V 88 lif 1 Main Rotor Casing CS00100 250vxM_ 250vM Jif lil 1 Main Rotor Casing CS00100 250V XL 250VL _____ T
102. r l il Li iy 1 52 49 50 48 39 1 35 Chapter 1 Principle of Operation and Construction 320VSD 320VMD and 320VLD 2 Dan Z a n e SS gs VT R S malar COS r e a RC m 6 EN GS 22 G r zz 2 2 7 60 CI C 63 SS an PARERE A kn a hk La Ao KN S srra Ke r E KN KKR N E O e K Ba mm m Eo AAA ar Li Ga 3 62 bend ier A 68 4 13 444 54 7 g E SS M z M um NN L 22 533 ded N S 220 Uh dira PALM a L 15 ve 2 UT i 6 4 iH CIT ET m nn f EE Yaa a i li ua en A DN am OS ANI S 8 isi y Di ry i tee x 2 ARTO o 2222222222 re EP Kir CE PEE EA a A rl BLA a 27 ma F r z m d L se K LA DAN ANS RANN NR Sree Ya es MS xt x 3 40 63 Lu e N m Rp NA AN 4 MES i m ES 4 da PIO JN N NS x Am 9 gt 8 e y gt k M a a K 2 SN a N K G 5 6 sma NI M
103. rential pressure oil supply system This system supplies lubrication oil under the effect of the differential pressure but uses pump pressurized oil as the capacity control oil and as the lubrication oil during startup of the compressor Type B Supplies pressurized oil for capacity control system Supplies pressurized oil for lubrication system Oil injection gt Side bearing female rotor Balance piston gt k Oil supply header Side bearing gt _ Rotor intermeshing Main bearing gt sections Thrust bearing gt Mechanical seal Capacity control Discharge port Unloader cylinder Pump pressurized oil line Fig 1 15 Type A Oil Supply System Always supplies pump pressurized oil for capacity control system Supplies pressurized oil for lubrication system at startup of compressor injects oil to main and side bearings After startup solenoid valve is closed and oil is branched at upstream point of oil pump for distribution to main and side bearings under differential pressure effect Oil supply header Oil injection gt Side bearing female rotor gt A Check Balance piston valve Side bearing gt Rotor 4 intermeshing A as Main bearing gt sections Thrust bearing gt X Solenoid Mechanical seal gt valve Capacity control Discharge port A Unloader cylinder gt oi pump
104. ructions concerned Be sure to turn off both the motor power switch and control system power switch before starting inspection and any other maintenance operation In addition take all necessary measures to prevent the power switches from being accidentally turned on during service operation If the switches are turned on during service operation operator s clothing or part of body could be caught in rotating parts of the compressor and motor that will start running possibly resulting in personal injury or death Also near areas under voltage there is a high risk of life threatening electric shock e When turning on or off the power switches be extremely careful not to suffer electric shock 3 2 1 Preparation for Disassembly On a base mounted compressor limit disassembly and inspection to the mechanical seals thrust bearings unloader cylinder and balance piston When other parts of the compressor must be disassembled and inspected remove the compressor from the base and move it to another place with an adequate space for efficient service operation 3 1 Chapter 3 Maintenance 3 2 2 Necessary Tools Materials and Equipment Tools used for assembling disassembling operations must be the specified tools in good condition Using vvorn out or damaged tools or tools inappropriate for the operation increases a risk of personal injury or damage to compressor components Select a dry sand and dust free place with a space
105. rust Bearing CS03800 320 7321A 39 LockNut o NG31 o31 AN21 40 Lock Washer NG32 021 AW21 N N N 42 Spacer Thrust Bearing CS04200 320 AR Alignment 43 ThrustBearing Gland CS04300 320 1 30 Da a A HexagonHeadBolt NB15520 055 M20x5 1 8 1 780201 78 saga ead bot lek sasn cso 620 L e head bolt lock washer C50469 0 320 48 Retainer Oil Seal o o CS04800 320VD 320 5 4 AS A 4 491 IO Ring 121600 JISB201G160 1 1 1 50 Oil Seal O 505010 320 0 SAW95x120xB 1 1 1 51 Seal Cover 1 CS051000 320BBS 3209 1 1 1 52 Gasket Seal Cover_____ CS05200 320N_ 320 1 G n Screw 54 Unloader Slide Valve o CS05400320VSD 32056 1 54 Unloader Slide Valve grooved 13205909 54 UnloaderSlide Valve CS05400 320VMD__ 320VM 07 72 1 f 54 UnloaderSlide Valve grooved 320vm 1 34 Unloader Slide Valve 1C805400 320VLD A _ 54 UnloaderSlide Valve grooved 320V 0 Screw 60 nloader Cylinder CS06000 320V uu Screw a ed LL Screw 6 Ring PA12 240 HSB2401240 1 1I 64 o UnloaderPiston CS06400 320U 65 O Ring hPPA I 200 JISB2401P200 66 CapSeal __________ CS06600 320 CAP 3BE200 67 Push Rod Unloader Slide CS0671 GV 320V 1 1 1 Valve 686 GuidePin 9 NH3206 016 06 x 16 69 LockNut
106. sing Fig 3 85 Driving in Alignment Pins h Check the unloader slide valve and variable Vi auxiliary slide valve for smooth movement Also check that the male rotor shaft can be rotated by hand 1 T xi A R k 7 Fig 3 86 Tightening Hexagon Head Cap Screws Fig 3 87 Tightening the Screws with Hydraulic with Torque Wrench Torque Wrench Large sized Models 5 Thrust Bearings a Install the thrust bearings and related parts paying attention to the following points e f removed thrust bearings P N 38 are reused check the M and F marks on the thrust bearing alignment spacers P N 42 and install the spacers in the original combinations with the thrust bearings While installing the thrust bearings prevent any foreign matter from getting into the thrust baring glands thrust bearing alignment spacers main bearings and bearing head as foreign material in any of these locations will prevent reestablishing the original thrust clearance Install each thrust bearing with the V mark on the bearing pointing toward the rotor see Fig 3 88 If the thrust bearing is installed in the wrong direction end clearance will become different from the original clearance because of the difference in end surface between the outer and inner races 3 34 4 z l El ay OLAM Fig 3 89 V Mark on Thrust Bearing t ock Nut Fig 3 92 Tightening the L Fig 3 93 Lock Washer Claws Be sure to i
107. sing a crane and chain block properly e Only a qualified person must operate a crane There will be an increased risk of accident due to falling down of the rotor if an unqualified operator handles a crane a After pulling out the rotor partway along the length of the main rotor casing attach a hemp rope or nylon belt to the rotor to suspend it from a crane Lift the rotor while drawing it out of the casing Do not use a wire rope as it will damage the rotor Either the male or the female rotor may be removed first When removing the female rotor first rotate it counterclockwise as you pull it out When the rotor comes out approximately two thirds of its length attach a belt on it and while lifting it slightly pull out the remaining part Be careful not to damage the bore surface of the main rotor casing with the rotor shaft ends b Support the removed rotor by its both shaft ends with V blocks so that the lobes will not touch the floor c Remove the other rotor in the same way as Step a and support it with V blocks by both shaft ends d Remove the hexagon head socket cap screw P N 454 securing the lock washer on the end of the Vi adjusting rod and remove the lock washer see Fig 3 58 The lock washer is not used on the products manufactured in and after 2003 3 25 Chapter 3 Maintenance Fig 3 56 Pulling Out the Female Rotor Fig 3 57 Pulling Out the Male Rotor e Turn the Vi adjusting rod in the bearing head counterclock
108. sket D 17 Bearing cover gasket G O dl 23 Balance piston cover gasket 52 Seal cover gasket 93 Suction flange gasket 96 Discharge flange gasket G 216 Lubricating oil flange gasket 252 Electromizer flange gasket 255 Aquamizer flange gasket 602 Female rotor side 219 Oil injection flange gasket bearing flange gasket 236 2597 flange spacer gasket All flanges are produced to the MYCOM standards ee o Bearing head gasket pH 345 420 525 660 rur sr UX7 Tar s s w 388 480 580 LL 200 250 93 Suction flange gasket 173 198 125A 150A 250A 350A 216 Lubrication oil flange gasket Discharge flange gasket G 143 173 198 250 100A 1 LESA 1 x KON 219 Oil injection flange gasket dn a 200CD 252 Electromizer flange gasket 118 i i un 80A zz mana si TA Ad 20A 25A 32A 50A 20A 4 4 O Ring Materials applicable to all models O Rings Materials except for O rings in mechanical seals Refrigerant Type O Ring Material Ammonia HFC City gas Helium Tools Standard Tools Stop ring priers large size Allen wrench set WAF width across flats in mm da i 3 12 O O WAF 4 0 WAF 5 o o o O WAF 6 il e il O wars WAF 10 o O
109. stalled first b Identify the location of the groove between the female rotor s lobes marked 1 and 2 c Suspend the male rotor from a crane or chain block and install it while mating its lobe marked 1 with the groove between the female rotor s lobes marked 1 and 2 and then rotate the male rotor until its end reaches halfway in the main rotor casing bore Detach the rope or strap from the male rotor and push it completely inward NOTE Proper mating between the male and female rotor lobes is essential to assure proper lobe to lobe contact and clearance If the original mating is disturbed irregular contact and clearance and hence irregular operating sound will result Make sure to keep the proper mating of the rotor lobes Fig 3 76 Installing the Male Rotor Fig 3 77 Rotors Installed in Position 3 31 Chapter 3 Maintenance 4 Suction Cover a Install the side bearings into the suction cover in the same way as for installing the main bearings into the bearing head Do not fail to attach the O rings P N 433 on the outside diameter of each side bearing The side bearings may be either clearance fitted or interference fitted in the bores in the suction cover like with the main bearings in the bearing head When installing an interference fitted bearing tap it only through a copper aluminum or plastic cushioning plate The pin will be easily aligned with the notch on the outer flange of each side
110. t of compression Volume of refrigerant gas just before opening of discharge port The Vi value is fixed at 2 63 3 65 or 5 80 for the conventional MYCOM compressors compressors with Vi at 2 63 are called the L port compressors those with Vi at 3 65 are called the M port compressors and those with Vi at 5 80 are called the H port compressors These designations are associated with the discharge port types A Volume of suction gas Compressed gas volume B C Fig 1 10 Internal Volume Ratio Vi Chapter 1 Principle of Operation and Construction 1 3 2 VVhy the Vi Needs to Be Changed The SCV Series Screw Compressors have a mechanism that allows adjusting the Vi in the worksite This adjusting mechanism is needed for the following two purposes 1 To adapt the Vi to the refrigerant used The internal volume ratio Vi can be expressed as a function of the internal pressure ratio as follows 1 rf lt ay Pd Where Pd discharge pressure Ps suction pressure K ratio of specific heats a constant specific to each refrigerant As seen from the formula the Vi corresponding to a certain pressure ratio varies with the type of refrigerant gas Therefore an adjustment of the Vi is needed to attain the optimum compression ratio for each type of refrigerant gas 2 To operate the compressor most efficiently under varying conditions Compressors of the same model will be used for a variety of applications whose load
111. t to H port position before shipment Move unloader slide valve to H port s no load position Turn Vi adjusting rod counterclockwise by the number of turns obtained from Fig 2 5 to move unloader slide valve to M port position Move unloader slide valve from no load position to full load position make sure it is within M port s 100 load position range then lock Vi adjusting rod Fig 2 4 Vi Changing Sequence from H Port to M Port 2 6 From H port to M port From H port to L port H gt M 160VS 160VM 160VL H L 160VS 160VM 160VL Displacement distance 16 mm 23 mm 27 mm Displacement distance 37 mm 45 mm 55 mm Number of tums of rod 7 2 9 2 10 8 oftumsofrod 14 8 18 22 H gt M 200VS 200VM 200VL H L 01 200VS 200VM 200VL Displacement distance 23 mm 28 mm 34 mm AA 46 mm 57 mm 69 mm Number of turns of rod 6 6 8 0 9 7 Number of turns of rod 13 1 16 3 19 7 kk HM LE Hk L 73 94 105 145 181 218 O Number of tums of rod 7 3 9 1 10 8 nu Number of tums ofrod 14 5 18 1 21 8 H M Hal 320VS 320VM 320VL Displacement distance 59 mm 50 mm 47 mm i 98 mm 98 mm 105 mm Number of turns of rod 13 11 10 Number of turns of rod 21 5 21 5 23 Fig 2 5 Number of Turns of Vi Adjusting Rod for Individual Models Reference Screw thread specifications of Vi adjusting rod 160V M20 x P2 5 mm 250V M36 x P3 5 mm 200V M30 x P3 5 mm 3
112. the bearing s outer race and the bearing retainer hook the wire end on the outer race and pull the bearing out as indicated by the arrow in Fig 3 46 e Remove the thrust bearing alignment spacer P N 42 and thrust bearing outer race spacer P N 41 behind the thrust bearing There is no alignment spacer on some models for structural reasons Store the thrust bearing outer race spacer and thrust bearing alignment spacer removed from the male rotor separately from those removed from the female rotor Both spacers have stamp marks identifying the rotor for which they are to be used see Fig 3 48 If they are reinstalled for a wrong rotor the end clearance between the discharge end surface of the rotor and the bearing head end surface will become incorrect resulting in problems such as poor compressor performance and seizure at the rotor end 3 21 Chapter 3 Maintenance 160 Thrust bearing 41 Thrust bearing outer race 2 spacer 24 gt 45 Hexagon head boat 81 81 8 46 Conicalspringwasher 8 8 8 2 250 Torsional slip vvasher Fig 3 48 Stamp Marks on Spacers 250 Thrust washer 3 22 N RL xl 4 Y Mes for at 2 C al d N 24 D Let nel E K PAY b 119 4 Dr N Fig 3 49 Compon
113. the use of the product for any purposes not intended by Mayekawa Liquid flow back operation Although the compressor normally sucks gaseous refrigerant it can suck liquid refrigerant due to such causes as a poorly adjusted or damaged expansion valve We call this state of compressor operation liquid flow back operation As the compressor cannot compress liquid it can be damaged when sucking any liquid Table of Contents Chapter 1 Principle of Operation and Construction tI 1 1 1 2 Refrigerant Gas Compression 5 5 1 2 kek PICTON hls e a e e PE ee AM A ee 1 3 t22 COMPpression PNI Se s b b b 1 4 1 20 Discharge NAGS a e e eee eee e een 1 4 t3 intemal Volume Rd NV ame O lid cieli 1 5 1 3 1 What Is the Internal Volume Ratio Vi iii 1 5 1 3 2 Why the Vi Needs to Be 4 ii 1 6 Mote Vahable VU Mechan s n o liacle o a Du XOR 1 8 14 Descrip on of G lnp nenis uU skala e e lella 1 11 li 1500 00 r RE eee Ye e e Re e PR 1 11 1 4 2 Sealing of MaleRotortoPreventRefrigerantGasleakage 1 11 TAS Joe ee onal aa c d daaa aaa mda zab 1 11 1 4 4 Oil Supply System Lubrication Oil and Capacity Control Hydraulic Oil 1 12 1 5 Model Designations of SCV Series Screw Compressors
114. tion flange Hexagon head bolt M20x55 8 M22x55 8 M24x65 02 24 75 97 Discharge flange Hexagon M22x55 4 M20x55 8 Mees MAMA head bolt M22x80 4 M20x80 8 Lubrication oil supply Hexagon head m aa M12x35 2 aag a ea flange Oil injection flange Hexagon head bolt D e E I M12x40 4 Electromizer flange Hexagon head bolt M12x35 4 M12x40 4 es Aquamizer flange Hexagon head bolt M12x35 2 1 M12x35 2 12 40 16 45 a 4 1 Chapter 4 Service Data l Hexagon socket head cap eee ku 00 7 M6x20 1 screw 454 Variable Vi auxiliary Hexagon socket head cap M4x20 M6x20 had M6x35 slide valve lock screw washer pe O ring gland Hexagon socket head cap M5x10 2 5 4 M5x10 4 screw hal Oil seal sleeve Set screW sis q m A M6x8 2 03 Female rotor side Hexagon head bolt ni 5 bearing oil supply flange Used for the compressors produced before 2003 Tightening Torques for Hexagon Socket Head Cap Screws Tightening Torques for Hexagon Head Bolts P N 45 of Thrust Bearing Glands 250V M16x45 60 1 600 Tightening Torques for Lock Nuts i 77 350 A0 02U 980082XCX 9095271582 a 610 79 70 O 98212 A60 90 90 CU 0113 27 1 130 2 970 5 100 8 200 10 120 12 300 14 830 17 660 20 800 23 450 28 240 4 2 Stop Rings quantity in parentheses 160V 200V 250V 320V H 102 2 H130 2 H160 2 H200 2 Side bearing H 102 2
115. tions of and damage to the product that result from any of the following causes e Malfunctions or damage resulting from natural disaster or other force majeure including windstorm intense rainfall flood tidal wave earthquake land subsidence thunderbolt and fire and any causes beyond the control of Mayekawa e Malfunctions or damage resulting from improper usage of the product examples of which are the following Malfunctions damage or deterioration due to misuse or unacceptable use of the product including improperly storing the product outdoors or under too hot humid conditions too frequent liquid flow back operation too frequent start stop cycles etc Malfunctions of or damage to the product resulting from the method of operation or control of those devices or equipment that are not supplied from Mayekawa Malfunctions or damage resulting from the use of refrigerants gases or lubrication oils not approved for use with the product or the use of the product under other conditions than those for which the product is designed Malfunctions or damage resulting from maintenance or inspection performed in other ways than those recommended by Mayekawa o Malfunctions or damage resulting from the use of other replacement parts than genuine Mayekawa parts Malfunctions or damage resulting from modifications to the product performed according to any instructions not given by Mayekawa Malfunctions or damage resulting from
116. ual to or lower than the atmospheric pressure before removing the compressor from the base The method for reducing the pressure varies with the refrigerating system for which the compressor is used Use any of the following methods whichever appropriate for the system Since almost all refrigerants have impacts on the environment it is essential to select the method that can assuredly prevent refrigerant gas from being discharged into the atmosphere Use a special refrigerant recovery unit if the system is provided with it e the system uses two or more compressors and any one of them is available for operation use the compressor to recover the refrigerant 3 2 e Use a portable compressor designed for the refrigerant recovery purpose e Release the pressure into the low pressure section inside the compressor using a bypass circuit 2 Disconnecting the Connections The following preparation is necessary before disconnecting the connections on the compressor e Prepare containers to receive oil that will flow out of the compressor when the oil and refrigerant piping is disconnected e f ammonia is used as the refrigerant maintain good ventilation to prevent suffering from strong odor that will be given off even under low refrigerant pressures Disconnect the connections in the following sequence 1 Coupling 2 Suction piping 3 Discharge piping 4 Oil piping 5 Fluid injection 6 Electromizer 7 Oil injection
117. ust before the start of compression and the volume of the cavity just before the discharge of the compressed gas see section 1 3 for further details In addition the SCV Series compressors employ O profile screw lobes for the rotors which minimize leaks and thus enhance the compression efficiency G Rotor sin Suction port Unloader push rod _ Unloader piston LL A Hu i P E r Vi adjusting rod cap nut p E Unloader indicator rr 221 SSA A Vi adjusting rod Oil hole Variable Vi auxiliary Unloader cylinder Male rotor m 4 slide valve th Ma yr m Unloader slide valve E 4 et Ak aar x T 1 SCV plate J E 4 a a te SSN G ac s su LI xa ale a a AA PA Sa elele A F a z z zz vz Discharge port AM f T Female rotor Oil return hole Fig 1 1 Sectional View of SCV Series Screw Compressor Typical 1 1 Chapter 1 Principle of Operation and Construction 1 2 Refrigerant Gas Compression Mechanism Inside the main rotor casing there are the male rotor number of screw lobes 4 and female rotor number of screvv lobes 6 intermeshing and rotating in the opposing directions each other Together vvith the rotor casing these tvvo rotors constitute the essential elements of the compressor for sucking and compressin
118. when counting the number of turns of the rod 2 4 d Turn the Vi adjusting rod counterclockwise by the number of turns determined in step 3 The Vi setting will be changed from the H port setting to the M port setting as shown in Sequence 3 in Fig 2 4 e While holding the Vi adjusting rod against rotation lock the rod by tightening the lock nut f Install the domed cap nut to the end of the Vi adjusting rod and tighten it Do not fail to install the conical spring washer between the hexagon nut and domed cap nut to prevent detachment of the cap nut q oo ka i l pi di a G ir 89 oy SS YE Fig 2 3 Conical Spring Washer 5 Pull the unloader piston to move the unloader slide valve to the full load 100 position Sequence 4 in Fig 2 4 If the pointer of the unloader indicator aligns with the 100 graduation for the port in question on the dial the Vi is correctly adjusted to that port The M and H graduation marks are rather large in width This is because there is a slight difference in indication of the M and H positions among the 13 compressor models i e 160S M L 200S M L 250S M L LL and 320S M L due to difference in rotor length The setting may be considered correct if the needle indicates any point in the width of the graduation mark 2 5 Chapter 2 Essential Points for Operation Hovv to Change Vi from H Port to M port Unloader slide valve is se
119. wise to set it to the L port position and then use the eye bolt to push the unloader slide valve to the no load position Next apply oil to the suction cover gasket and affix it to the main rotor casing Insert a few screws in the main rotor casing to retain the gasket in position Push the alignment pins toward the main rotor casing f Slide the suction cover on the workbench to first align the unloader push rod with the O ring gland in the suction cover and then align the shaft ends of the rotors with the side bearings Finally push the suction cover in parallel with the shaft axes to put it together with the main rotor casing Fig 3 82 Assembling the Suction Cover with Fig 3 83 Assembling the Suction Cover with Main Rotor Casing on Workbench Main Rotor Casing Using a Crane For large sized compressor models assembling the suction cover with the main rotor casing by sliding the cover on the workbench is difficult Instead place the main rotor casing on the edge of the workbench and lift the suction cover with a crane see Fig 3 83 It is recommended to use a chain block with the crane to be able to make fine up and down adjustments 3 33 Chapter 3 Maintenance g Drive the alignment pins into position Then tighten the hexagon socket head cap screvvs to the specified torque see Tightening Torques for Hexagon Head Cap Screws in Chapter 4 ea Fig 3 84 Suction Cover Assembled with Main Rotor Ca
120. wise until its end disengages from the variable Vi auxiliary slide valve and then pull the rod out of the bearing head Keep the thrust washers P N 449 together with the Vi adjusting rod f Return to the suction side Pull the unloader slide valve and the variable Vi auxiliary slide valve out of the main rotor casing by holding the unloader push rod Then hold the variable Vi auxiliary slide valve to pull out the unloader push rod and separate the variable Vi auxiliary slide valve and unloader slide valve Fig 3 58 Removing the Lock Washer Products in and before 2003 Fig 3 60 Pulling Out the Variable Vi Auxiliary Fig 3 61 Separating the Variable Vi Auxiliary Valve and Unloader Slide Valve Valve and Unloader Slide Valve 3 26 nspecting the Rotors Main Rotor Casing Variable Vi Auxiliary Slide Valve and Unloader Slide Valve a Check that the shaft end surfaces and the O ring contact surface at the mechanical seal area of each rotor are free of damage b Inspect the rotor surfaces in the areas of engagement between the male and female rotors and the lobe contours for damage and wear There should be no damage on these surfaces under normal operating conditions of the compressor If they have damage a probable cause may be foreign materials entering the compressor The suction gas filter and or oil filter should then be inspected c Inspect the surfaces of the unloader slide valve and variable Vi auxiliary slide valve that ru
121. xed axial port of the size corresponding to Vi 5 1 but the radial port in the unloader slide valve is made variable to constitute a variable Vi mechanism This is achieved by making the full load end of the unloader slide valve which is fixed with the conventional models variable as necessary Fig 1 12 compares the discharge ports or the fixed and variable Vi compressors Fig 1 13 shows the detail of the variable Vi mechanism Conventional compressors fixed Vi SCV Series compressors variable Vi Both axial and radial ports fixed e Axial port fixed radial port variable 1 The size of the axial port in the bearing head 2 The size of the radial port in the unloader slide valve Fig 1 12 Discharge Ports of Variable and Non variable Vi Compressors 1 8 Unloader cylinder cover P N 74 o 3 Variable Vi auxiliary slide valve P N 289 2 Unloader cylinder P N 60 Unloader piston 5 P N 64 Indicator cam SEA P N 77 1 DI EL Unlaoder push rod P N 67 Unloader slide valve PIN 54 uu e ON Vi adjusting P N 444 4 Thrust washer lt lt P N 449 N OF Fig 1 13 Variable Vi Mechanism The greatest benefit provided by properly setting the Vi value is that the rotor driving power brake horse power is made optimum for the load The refrigeration capacity generally changes little even if the Vi is varied However the efficiency of the brake horse power

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